2010 SUBARU LEGACY SERVICE MANUAL


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Table of contents :
GENERAL INFORMATION SECTION
FOREWORD FW
1. Foreword
A: FOREWORD
HOW TO USE THIS MANUALS HU
1. How to Use This Manuals
A: HOW TO USE THIS MANUALS
1. STRUCTURE
2. CONTENTS
3. COMPONENT
4. DEFINITION OF “NOTE”, “CAUTION” AND “WARNING”
5. SPECIFICATION
6. INSPECTION
7. MAINTENANCE
8. DIAGNOSIS
9. SI UNITS
10. EXPLANATION OF TERMINOLOGY
SPECIFICATIONS SPC
1. LEGACY
A: DIMENSION
1. SEDAN MODEL
B: ENGINE
C: ELECTRICAL
D: TRANSMISSION
1. MT
2. AT
3. CVT
E: STEERING
F: SUSPENSION
G: BRAKE
H: TIRE
I: CAPACITY
2. OUTBACK
A: DIMENSION
1. OUTBACK MODEL
B: ENGINE
C: ELECTRICAL
D: TRANSMISSION
1. MT
2. AT
3. CVT
E: STEERING
F: SUSPENSION
G: BRAKE
H: TIRE
I: CAPACITY
PRECAUTION PC
1. Precaution
A: CAUTION
1. VEHICLE DYNAMICS CONTROL (VDC)
2. ELECTRONIC PARKING BRAKE
3. BRAKE FLUID
4. RADIATOR FAN
5. ROAD TEST
6. AIRBAG
7. AIRBAG AND SEAT BELT PRETENSIONER DISPOSAL
8. AIRBAG MODULE
9. AIRBAG SPECIAL TOOL
10. WINDOW
11. WINDOW ADHESIVE
12. OIL
13. FUEL
14. ENGINE COOLANT
15. AIR CONDITIONER REFRIGERANT
16. REMOVAL AND INSTALLATION OPERATION OF HOSES, ETC.
1. Before the removal and installation operation of hoses, etc.
2. Removal and installation operation of hoses, etc. during the inspection
NOTE NT
1. Note
A: BASIC REPAIR HINT
1. APPEARANCE
2. PROTECTION OF VEHICLE UNDER MAINTENANCE AND PREPARATION OF TOOLS/ EQUIPMENT
3. SAFETY
4. SERVICE OPERATION
5. REMOVED PART
6. WHEN REMOVING BATTERY
B: NOTE
1. FASTENERS NOTICE
2. STATIC ELECTRICITY DAMAGE
3. BATTERY
4. BACKUP/POWER SUPPLY FUSE
5. IMMOBILIZER RELATED PART
6. SERVICE PARTS
7. PROTECTING VEHICLE UNDER MAINTENANCE
8. ENSURING SECURITY DURING WORK
9. LIFT AND JACK
. SUPPORT LOCATIONS
. PANTOGRAPH JACK
. Lift
. RIGID RACK
. PLATE LIFT
. Jack-up point (when using garage jack)
10. TIE-DOWNS
. TIE-DOWN LOCATION
. CHAIN DIRECTION AT TIE-DOWN CONDITION
. TIE-DOWN RANGE
. VEHICLE SINKING VOLUME AT TIE-DOWN CONDITION
. NOTES FOR THE USE OF TIE-DOWN HOOK
11. TOWING
12. FRONT HOOD DAMPER STAY
13. GENERAL SCAN TOOL
14. AWD CIRCUIT MEASURES
15. SPEEDOMETER TEST
16. BRAKE TEST
17. ON THE CAR WHEEL BALANCING
IDENTIFICATION ID
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER & LABEL LOCATIONS
2. MEANING OF V.I.N.
3. MODEL NUMBER PLATE
. BM9AY4M
. ENGINE
. TRANSMISSION
. Rear differential
. OPTION
RECOMMENDED MATERIALS RM
1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
2. FUEL
3. LUBRICANTS
4. FLUID
5. COOLANT
6. REFRIGERANT
7. GREASE
8. ADHESIVE
9. SEAL MATERIAL
PRE-DELIVERY INSPECTION PI
1. Pre-delivery Inspection
A: GENERAL DESCRIPTION
B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE
1. APPEARANCE
2. TIRE
3. FUSE
4. LOCK/UNLOCK AND OPEN/CLOSE OPERATION CHECKS OF DOORS.
5. CHILD SAFETY LOCK SYSTEM
6. OPEN/CLOSE OPERATION CHECKS OF TRUNK LID
7. TRUNK LID RELEASE HANDLE
8. LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS OF REAR GATE
9. FUEL LID OPENER LEVER
10. ACCESSORY
11. OPERATION CHECK OF FRONT HOOD LOCK RELEASE SYSTEM
12. BATTERY
13. BRAKE FLUID
14. ENGINE OIL
15. TRANSMISSION GEAR OIL
16. CVT FRONT DIFFERENTIAL GEAR OIL
17. ENGINE COOLANT
18. CLUTCH FLUID
19. WINDOW WASHER FLUID
20. FRONT HOOD LATCH
21. KEYLESS ENTRY SYSTEM
22. SECURITY SYSTEM (ALARM SYSTEM)
23. SEAT
24. SEAT BELT
25. TPMS
26. IMMOBILIZER SYSTEM
27. STARTING CONDITION
28. EXHAUST SYSTEM
29. INDICATOR LIGHT AND WARNING LIGHT
30. HEATER & VENTILATION
31. AIR CONDITIONER
32. CLOCK
33. AUDIO
34. NAVIGATION SYSTEM
35. ACCESSORY POWER SUPPLY SOCKET
36. LIGHTING SYSTEM
37. WIPER DEICER
38. ILLUMINATION CONTROL
39. WINDOW WASHER
40. WIPER
41. POWER WINDOW
42. SUNROOF
43. DOOR MIRROR
44. PARKING BRAKE
45. BRAKE TEST
46. AT SHIFT CONTROL
47. MT SHIFT CONTROL
48. CRUISE CONTROL
49. ATF LEVEL
50. CVTF
51. AT FRONT DIFFERENTIAL OIL
52. POWER STEERING FLUID LEVEL
53. OIL LEAKAGE
54. WATER LEAK TEST
55. APPEARANCE CHECK 2
PERIODIC MAINTENANCE SERVICES PM
1. General Description
A: GENERAL DESCRIPTION
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. U.S.
2. CANADA
B: MAINTENANCE SCHEDULE 2
3. Engine Oil
A: INSPECTION
B: REPLACEMENT
4. Engine Oil Filter
A: REPLACEMENT
5. Spark Plug
A: REPLACEMENT
6. V-belt
A: INSPECTION
B: REPLACEMENT
7. Timing Belt
A: INSPECTION
1. SOHC MODEL (INSPECTION OF TIMING BELT POSITION)
2. SOHC MODEL (OTHER INSPECTIONS)
3. DOHC MODEL (INSPECTION OF TIMING BELT POSITION)
4. DOHC MODEL (OTHER INSPECTIONS)
B: REPLACEMENT
8. Fuel Line
A: INSPECTION
9. Fuel Filter
A: REPLACEMENT
B: INSPECTION
10. Air Cleaner Element
A: REPLACEMENT
11. Cooling System
A: INSPECTION
1. RADIATOR
2. RADIATOR CAP
3. COOLING FAN
4. COOLING SYSTEM
12. Engine Coolant
A: REPLACEMENT
13. Clutch System
A: INSPECTION AND ADJUSTMENT
14. Transmission Gear Oil
A: INSPECTION
B: REPLACEMENT
15. Automatic Transmission Fluid
A: INSPECTION
B: REPLACEMENT
16. CVTF
A: REPLACEMENT
17. Front & Rear Differential Gear Oil
A: INSPECTION
1. FRONT DIFFERENTIAL (MT MODEL)
2. FRONT DIFFERENTIAL (AT MODEL)
3. REAR DIFFERENTIAL
B: REPLACEMENT
1. FRONT DIFFERENTIAL (MT MODEL)
2. FRONT DIFFERENTIAL (AT MODEL)
3. FRONT DIFFERENTIAL (CVT MODEL)
4. REAR DIFFERENTIAL
18. Brake Line
A: INSPECTION
1. BRAKE LINE
2. SERVICE BRAKE
3. BRAKE SERVO SYSTEM
19. Brake Fluid
A: INSPECTION
B: REPLACEMENT
20. Disc Brake Pad and Disc
A: INSPECTION
21. Brake Lining and Drum
A: INSPECTION
B: ADJUSTMENT
22. Suspension
A: INSPECTION
1. FRONT SUSPENSION BALL JOINT
2. REAR SUSPENSION BALL JOINT
3. FRONT, REAR SUSPENSION BUSHING
4. WHEEL ARCH HEIGHT
5. WHEEL ALIGNMENT
6. OIL LEAKAGE OF STRUT AND SHOCK ABSORBER
7. TIGHTNESS OF BOLTS AND NUTS
8. DAMAGE TO SUSPENSION PARTS
23. Wheel Bearing
A: INSPECTION
1. FRONT WHEEL BEARING
2. REAR WHEEL BEARING
24. Axle Boots & Joints
A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
2. PROPELLER SHAFT
25. Tire Rotation
A: INSPECTION
26. Steering System (Power Steering)
A: INSPECTION
1. STEERING WHEEL
2. STEERING SHAFT JOINT
3. GEARBOX
4. TIE-ROD
5. GEARBOX BOOTS
27. A/C Filter
A: REPLACEMENT
ENGINE 1 SECTION
FUEL INJECTION (FUEL SYSTEMS) FU(H4SO)
1. General Description
A: SPECIFICATION
B: COMPONENT
1. INTAKE MANIFOLD
2. AIR INTAKE SYSTEM
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
4. FUEL TANK
5. FUEL LINE
6. FUEL FILLER PIPE
7. FUEL PUMP
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Throttle Body
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. THROTTLE SENSOR (METHOD WITH CIRCUIT TESTER)
2. THROTTLE SENSOR (METHOD WITH SUBARU SELECT MONITOR)
3. OTHER INSPECTIONS
3. Intake Manifold
A: REMOVAL
1. INTAKE MANIFOLD
2. MULTI-FUNCTION DUCT ASSEMBLY
B: INSTALLATION
1. INTAKE MANIFOLD
2. MULTI-FUNCTION DUCT ASSEMBLY
C: INSPECTION
4. Engine Coolant Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Crankshaft Position Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CRANKSHAFT POSITION SENSOR (METHOD WITH CIRCUIT TESTER)
2. CRANKSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE)
3. OTHER INSPECTIONS
6. Camshaft Position Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CAMSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE)
2. OTHER INSPECTIONS
7. Knock Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Throttle Position Sensor
A: SPECIFICATION
9. Mass Air Flow and Intake Air Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CHECK MASS AIR FLOW SENSOR UNIT
2. CHECK INTAKE AIR TEMPERATURE SENSOR UNIT
3. OTHER INSPECTIONS
10. Manifold Absolute Pressure Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
11. EGR Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
12. Fuel Injector
A: REMOVAL
B: INSTALLATION
C: INSPECTION
13. Variable Valve Lift Diagnosis Oil Pressure Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
14. Oil Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
15. Front Oxygen (A/F) Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
16. Rear Oxygen Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
17. Engine Control Module (ECM)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
18. Main Relay
A: REMOVAL
B: INSTALLATION
C: INSPECTION
19. Fuel Pump Relay
A: REMOVAL
B: INSTALLATION
C: INSPECTION
20. Electronic Throttle Control Relay
A: REMOVAL
B: INSTALLATION
C: INSPECTION
21. Fuel
A: PROCEDURE
1. RELEASING OF FUEL PRESSURE
2. DRAINING FUEL (WITH SUBARU SELECT MONITOR)
3. DRAINING FUEL (THROUGH THE FUEL FILLER HOSE)
22. Fuel Tank
A: REMOVAL
B: INSTALLATION
C: INSPECTION
23. Fuel Filler Pipe
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
24. Fuel Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
25. Fuel Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
26. Fuel Sub Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
27. Fuel Filter
A: REMOVAL
B: INSTALLATION
28. Fuel Delivery and Evaporation Lines
A: REMOVAL
B: INSTALLATION
1. INSTALLATION OF EVAPORATION PIPE
2. CONNECTING THE FUEL LINE QUICK CONNECTOR
3. EVAPORATION HOSE CONNECTION
4. CONNECTING THE EVAPORATION LINE QUICK CONNECTOR
C: INSPECTION
29. Fuel System Trouble in General
A: INSPECTION
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4SO)
1. General Description
A: CAUTION
B: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Front Catalytic Converter
A: REMOVAL
B: INSTALLATION
C: INSPECTION
3. Rear Catalytic Converter
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Canister
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Purge Control Solenoid Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. PURGE CONTROL SOLENOID VALVE
2. OTHER INSPECTIONS
6. EGR Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Fuel Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Fuel Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
9. Fuel Sub Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Fuel Tank Pressure Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. FUEL TANK PRESSURE SENSOR
2. OTHER INSPECTIONS
11. Drain Filter
A: SPECIFICATION
12. Drain Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
13. PCV Hose Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
14. PCV Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. PCV VALVE
2. OTHER INSPECTIONS
INTAKE (INDUCTION) IN(H4SO)
1. General Description
A: COMPONENT
B: CAUTION
2. Air Cleaner Element
A: REMOVAL
B: INSTALLATION
C: INSPECTION
3. Air Cleaner Case
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Air Intake Boot
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Air Intake Duct
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Resonator Chamber
A: REMOVAL
B: INSTALLATION
C: INSPECTION
MECHANICAL ME(H4SO)
1. General Description
A: SPECIFICATION
B: COMPONENT
1. V-BELT
2. TIMING BELT
3. CYLINDER HEAD AND CAMSHAFT
4. VALVE ROCKER ASSY
5. CYLINDER HEAD AND VALVE ASSEMBLY
6. CYLINDER BLOCK
7. CRANKSHAFT AND PISTON
8. ENGINE MOUNTING
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Compression
A: INSPECTION
3. Idle Speed
A: INSPECTION
4. Ignition Timing
A: INSPECTION
1. METHOD WITH SUBARU SELECT MONITOR
2. METHOD WITH TIMING LIGHT
5. Intake Manifold Vacuum
A: INSPECTION
6. Engine Oil Pressure
A: INSPECTION
7. Fuel Pressure
A: INSPECTION
8. Valve Clearance
A: INSPECTION
B: ADJUSTMENT
9. Engine Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Engine Mounting
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
11. Preparation for Overhaul
A: PROCEDURE
12. V-belt
A: REMOVAL
1. V-BELT
2. V-BELT TENSIONER ASSEMBLY AND IDLER PULLEY
B: INSTALLATION
1. V-BELT
2. V-BELT TENSIONER ASSEMBLY AND IDLER PULLEY
C: INSPECTION
13. Crank Pulley
A: REMOVAL
B: INSTALLATION
1. METHOD WITHOUT ANGLE GAUGE
2. METHOD WITH ANGLE GAUGE
C: INSPECTION
14. Timing Belt Cover
A: REMOVAL
B: INSTALLATION
C: INSPECTION
15. Timing Belt
A: REMOVAL
1. TIMING BELT
2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
2. TIMING BELT
C: INSPECTION
1. TIMING BELT
2. AUTOMATIC BELT TENSION ADJUSTER
3. BELT TENSION PULLEY
4. BELT IDLER
16. Cam Sprocket
A: REMOVAL
B: INSTALLATION
C: INSPECTION
17. Crank Sprocket
A: REMOVAL
B: INSTALLATION
C: INSPECTION
18. Valve Rocker Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. INTAKE VALVE ROCKER ASSEMBLY
2. EXHAUST VALVE ROCKER ASSEMBLY
19. Camshaft
A: REMOVAL
B: INSTALLATION
C: INSPECTION
20. Cylinder Head
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. CYLINDER HEAD
2. VALVE SEAT
3. VALVE GUIDE
4. INTAKE AND EXHAUST VALVE
5. VALVE SPRING
6. INTAKE AND EXHAUST VALVE OIL SEAL
21. Cylinder Block
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. CYLINDER BLOCK
2. CYLINDER AND PISTON
3. PISTON AND PISTON PIN
4. PISTON RING
5. CONNECTING ROD
6. CRANKSHAFT AND CRANKSHAFT BEARING
22. Oil Switching Solenoid Valve
A: REMOVAL
1. RH SIDE
2. LH SIDE
B: INSTALLATION
1. RH SIDE
2. LH SIDE
23. Intake and Exhaust Valve
A: SPECIFICATION
24. Piston
A: SPECIFICATION
25. Connecting Rod
A: SPECIFICATION
26. Crankshaft
A: SPECIFICATION
27. Engine Trouble in General
A: INSPECTION
28. Engine Noise
A: INSPECTION
EXHAUST EX(H4SO)
1. General Description
A: COMPONENT
B: CAUTION
2. Front Exhaust Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
3. Center Exhaust Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Rear Exhaust Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Muffler
A: REMOVAL
B: INSTALLATION
C: INSPECTION
COOLING CO(H4SO)
1. General Description
A: SPECIFICATION
B: COMPONENT
1. WATER PUMP
2. RADIATOR & RADIATOR FAN
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Radiator Fan System
A: WIRING DIAGRAM
B: INSPECTION
3. Engine Coolant
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
2. FILLING OF ENGINE COOLANT
B: ADJUSTMENT
1. PROCEDURE TO ADJUST THE SUBARU SUPER COOLANT CONCENTRATION
4. Water Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Thermostat
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Radiator
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Radiator Cap
A: INSPECTION
8. Radiator Main Fan and Fan Motor
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
9. Radiator Sub Fan and Fan Motor
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
10. Reservoir Tank
A: REMOVAL
B: INSTALLATION
C: INSPECTION
11. Engine Cooling System Trouble in General
A: INSPECTION
LUBRICATION LU(H4SO)
1. General Description
A: SPECIFICATION
B: COMPONENT
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Oil Pressure System
A: WIRING DIAGRAM
B: INSPECTION
3. Engine Oil
A: INSPECTION
B: REPLACEMENT
4. Oil Pump
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. TIP CLEARANCE
2. CASE CLEARANCE
3. SIDE CLEARANCE
4. OIL RELIEF VALVE
5. OIL PUMP CASE
6. FRONT OIL SEAL
5. Oil Pan and Strainer
A: REMOVAL
1. OIL PAN
2. CYLINDER BLOCK LOWER
B: INSTALLATION
1. OIL PAN
2. CYLINDER BLOCK LOWER
C: INSPECTION
6. Oil Pressure Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Engine Oil Cooler
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Oil Catch Tank
A: REMOVAL
B: INSTALLATION
C: INSPECTION
9. Scavenge Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Oil Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. INSPECTING UNION BOLT WITH FILTER
2. OTHER INSPECTIONS
11. Engine Oil Filter
A: REMOVAL
B: INSTALLATION
C: INSPECTION
12. Oil Level Switch
A: REMOVAL
B: INSTALLATION
C: WIRING DIAGRAM
D: INSPECTION
1. INSPECTION WHILE OIL LEVEL SWITCH WARNING LIGHT IS ON
2. OTHER INSPECTIONS
13. Engine Lubrication System Trouble in General
A: INSPECTION
SPEED CONTROL SYSTEMS SP(H4SO)
1. General Description
A: SPECIFICATION
B: COMPONENT
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Accelerator Pedal
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: INSPECTION
1. CHECK ACCELERATOR PEDAL SENSOR AREA (METHOD WITH CIRCUIT TESTER)
2. CHECK ACCELERATOR PEDAL SENSOR AREA (METHOD WITH SUBARU SELECT MONITOR)
3. OTHER INSPECTIONS
IGNITION IG(H4SO)
1. General Description
A: SPECIFICATION
B: COMPONENT
C: CAUTION
2. Spark Plug
A: REMOVAL
1. RH SIDE
2. LH SIDE
B: INSTALLATION
1. RH SIDE
2. LH SIDE
C: INSPECTION
3. Ignition Coil
A: REMOVAL
B: INSTALLATION
C: INSPECTION
STARTING/CHARGING SYSTEMS SC(H4SO)
1. General Description
A: SPECIFICATION
1. 2.5 L MODEL
2. 3.6 L MODEL
B: COMPONENT
1. STARTER
2. GENERATOR
3. GENERATOR BRACKET
C: CAUTION
2. Starter
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. SWITCH ASSEMBLY
2. SWITCH ASSEMBLY OPERATION
3. PERFORMANCE TEST
3. Generator
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. 2.5 L MODEL
2. 3.6 L MODEL
D: ASSEMBLY
E: INSPECTION
1. DIODE
2. ROTOR
3. STATOR COIL
4. BRUSH
5. BALL BEARING (FRONT SIDE)
4. Battery
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. EXTERNAL PARTS
2. ELECTROLYTE LEVEL
3. SPECIFIC GRAVITY OF ELECTROLYTE
D: MEASUREMENT
1. JUDGMENT OF BATTERY IN CHARGED CONDITION
2. CHECK CONDITION OF CHARGE WITH HYDROMETER
3. NORMAL CHARGING
4. QUICK CHARGING
ENGINE (DIAGNOSTICS) EN(H4SO)(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
1. ENGINE
2. Check List for Interview
A: CHECK
1. CHECK LIST NO. 1
2. CHECK LIST NO. 2
3. General Description
A: CAUTION
B: INSPECTION
1. BATTERY
2. ENGINE GROUND
C: NOTE
D: PREPARATION TOOL
4. Electrical Component Location
A: LOCATION
1. CONTROL MODULE
2. SENSOR
3. SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS
4. TRANSMISSION
5. Engine Control Module (ECM) I/O Signal
A: ELECTRICAL SPECIFICATION
6. Engine Condition Data
A: ELECTRICAL SPECIFICATION
7. Data Link Connector
A: NOTE
8. General Scan Tool
A: OPERATION
1. HOW TO USE GENERAL SCAN TOOL
2. MODE $01: (CURRENT POWERTRAIN DIAGNOSTIC DATA)
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)
4. MODE $03 (EMISSION-RELATED POWERTRAIN DTC)
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
6. MODE $06
7. MODE $07
8. MODE $09
9. Subaru Select Monitor
A: OPERATION
1. HOW TO USE THE SUBARU SELECT MONITOR
2. READ CURRENT DATA FOR ENGINE (NORMAL MODE)
3. READ CURRENT DATA FOR ENGINE (OBD MODE)
4. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE)
5. V.I.N REGISTRATION
10. Read Diagnostic Trouble Code (DTC)
A: OPERATION
1. SUBARU SELECT MONITOR
2. GENERAL SCAN TOOL
11. Inspection Mode
A: PROCEDURE
1. PREPARATION FOR THE INSPECTION MODE
2. SUBARU SELECT MONITOR
3. GENERAL SCAN TOOL
12. Drive Cycle
A: PROCEDURE
1. PREPARATION FOR DRIVE CYCLE
2. DRIVE CYCLE A
3. DRIVE CYCLE B
4. DRIVE CYCLE C
5. DRIVE CYCLE D
DRIFT DIAGNOSIS
STUCK DIAGNOSIS
6. DRIVE CYCLE E
7. DRIVE CYCLE F
8. DRIVE CYCLE H
13. Clear Memory Mode
A: OPERATION
1. SUBARU SELECT MONITOR
2. GENERAL SCAN TOOL
14. System Operation Check Mode
A: OPERATION
15. Malfunction Indicator Light
A: PROCEDURE
B: ACTIVATION OF MALFUNCTION INDICATOR LIGHT
C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON
D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF
E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK
F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING
16. Diagnostics for Engine Starting Failure
A: PROCEDURE
B: STARTER MOTOR CIRCUIT
C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM)
D: IGNITION CONTROL SYSTEM
E: FUEL PUMP CIRCUIT
F: FUEL INJECTOR CIRCUIT
17. List of Diagnostic Trouble Code (DTC)
A: LIST
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1)
B: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2)
C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
D: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)
E: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)
F: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
G: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
H: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
I: DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)
J: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1)
K: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)
L: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)
M: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE
N: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT
O: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
P: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT
Q: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT
R: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE
S: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
T: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
U: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
V: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
W: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW
X: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH
Y: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
Z: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION
AA: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
AB: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
AC: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
AD: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
AE: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)
AF: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)
AG: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
AH: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
AI: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)
AJ: DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2)
AK: DTC P0171 SYSTEM TOO LEAN (BANK 1)
AL: DTC P0172 SYSTEM TOO RICH (BANK 1)
AM: DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE
AN: DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT
AO: DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT
AP: DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE
AQ: DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW
AR: DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH
AS: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW
AT: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH
AU: DTC P0301 CYLINDER 1 MISFIRE DETECTED
AV: DTC P0302 CYLINDER 2 MISFIRE DETECTED
AW: DTC P0303 CYLINDER 3 MISFIRE DETECTED
AX: DTC P0304 CYLINDER 4 MISFIRE DETECTED
AY: DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)
AZ: DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)
BA: DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT
BB: DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE
BC: DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR)
BD: DTC P0341 CAMSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR)
BE: DTC P0400 EXHAUST GAS RECIRCULATION FLOW
BF: DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)
BG: DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
BH: DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
BI: DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
BJ: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR
BK: DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
BL: DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
BM: DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
BN: DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
BO: DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
BP: DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
BQ: DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE
BR: DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW
BS: DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH
BT: DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
BU: DTC P0500 VEHICLE SPEED SENSOR “A”
BV: DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
BW: DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
BX: DTC P0512 STARTER REQUEST CIRCUIT
BY: DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
BZ: DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
CA: DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE
CB: DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)
CC: DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
CD: DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)
CE: DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)
CF: DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)
CG: DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)
CH: DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)
CI: DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)
CJ: DTC P1160 RETURN SPRING FAILURE
CK: DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
CL: DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT)
CM: DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT)
CN: DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT)
CO: DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT)
CP: DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT)
CQ: DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT)
CR: DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT)
CS: DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT)
CT: DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT
CU: DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
CV: DTC P1602 CONTROL MODULE PROGRAMMING ERROR
CW: DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
CX: DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
CY: DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE
CZ: DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
DA: DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
DB: DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP PERFORMANCE
DC: DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT
DD: DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT
DE: DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT
DF: DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT
DG: DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION
DH: DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION
DI: DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE
DJ: DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW
DK: DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH
DL: DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION
DM: DTC U0101 CAN (TCU) DATA NOT LOADED
DN: DTC U0122 CAN (VDC) DATA NOT LOADED
DO: DTC U0140 CAN (BCU) DATA NOT LOADED
DP: DTC U0402 CAN (TCU) DATA ABNORMAL
DQ: DTC U0416 CAN (VDC) DATA ABNORMAL
DR: DTC U0422 CAN (BCU) DATA ABNORMAL
19. General Diagnostic Table
A: INSPECTION
1. ENGINE
GENERAL DESCRIPTION GD(H4SO)
1. List of Diagnostic Trouble Code (DTC)
A: LIST
2. Diagnostic Trouble Code (DTC) Detecting Criteria
A: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1)
1. OUTLINE OF DIAGNOSIS
. Normal
. Low NG
. High NG
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
B: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2)
1. OUTLINE OF DIAGNOSIS
C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
D: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
E: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
F: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
G: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
H: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
I: DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
J: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
K: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)
1. OUTLINE OF DIAGNOSIS
L: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)
1. OUTLINE OF DIAGNOSIS
M: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
N: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
O: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
P: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
Q: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
R: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
S: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
T: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
U: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
V: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
W: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
X: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
Y: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
Z: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AA: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AB: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AC: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AD: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AE: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AF: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AG: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
AH: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
Diagnostic method
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
6. ENABLE CONDITION
7. GENERAL DRIVING CYCLE
8. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AI: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION (USED ONLY FOR MALFUNCTION JUDGMENT)
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AJ: DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AK: DTC P0171 SYSTEM TOO LEAN (BANK 1)
1. OUTLINE OF DIAGNOSIS
Diagnostic method
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AL: DTC P0172 SYSTEM TOO RICH (BANK 1)
1. OUTLINE OF DIAGNOSIS
Diagnostic method
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AM: DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
Drift Diagnosis
Stuck Diagnosis
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
DRIFT DIAGNOSIS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
6. ENABLE CONDITION
Stuck Diagnosis
7. GENERAL DRIVING CYCLE
8. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AN: DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AO: DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AP: DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AQ: DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AR: DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AS: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AT: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AU: DTC P0301 CYLINDER 1 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
180˚ Interval Difference Method
360˚ Interval Difference Method
720˚ Interval Difference Method
. FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas)
. Catalyst damage misfire (Misfire occurrence level damaging catalyst)
AV: DTC P0302 CYLINDER 2 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
AW: DTC P0303 CYLINDER 3 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
AX: DTC P0304 CYLINDER 4 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
AY: DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AZ: DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BA: DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BB: DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BC: DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
Abnormality Judgment
Normality Judgment
BD: DTC P0341 CAMSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BE: DTC P0400 EXHAUST GAS RECIRCULATION FLOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BF: DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BG: DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
1. OUTLINE OF DIAGNOSIS
0.04-inch Diagnosis
Mode Table for Evaporative Emission Control System Diagnosis
0.02-inch Diagnosis
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
0.04-inch Diagnosis
0.02-inch Diagnosis
4. GENERAL DRIVING CYCLE
0.04-inch Diagnosis
0.02-inch Diagnosis
5. DIAGNOSTIC METHOD
Purge control solenoid valve stuck open fault diagnosis
Purge control solenoid valve Open Fixation
Leak Diagnosis
Leak Diagnosis
BH: DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BI: DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BJ: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BK: DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BL: DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BM: DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
1. OUTLINE OF DIAGNOSIS
BN: DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
1. OUTLINE OF DIAGNOSIS
BO: DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BP: DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BQ: DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BR: DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BS: DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BT: DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BU: DTC P0500 VEHICLE SPEED SENSOR “A”
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BV: DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BW: DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BX: DTC P0512 STARTER REQUEST CIRCUIT
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BY: DTC P0513 INCORRECT IMMOBILIZER KEY
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
BZ: DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
Abnormality Judgment
Normality Judgment
CA: DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
Abnormality Judgment
CB: DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
CC: DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
CD: DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CE: DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CF: DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CG: DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CH: DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CI: DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CJ: DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CK: DTC P1160 RETURN SPRING FAILURE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
CL: DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CM: DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CN: DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CO: DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT)
1. OUTLINE OF DIAGNOSIS
CP: DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT)
1. OUTLINE OF DIAGNOSIS
CQ: DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT)
1. OUTLINE OF DIAGNOSIS
CR: DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT)
1. OUTLINE OF DIAGNOSIS
CS: DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT)
1. OUTLINE OF DIAGNOSIS
CT: DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT)
1. OUTLINE OF DIAGNOSIS
CU: DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITIONS
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CV: DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CW: DTC P1570 ANTENNA
1. OUTLINE OF DIAGNOSIS
CX: DTC P1571 REFERENCE CODE INCOMPATIBILITY
1. OUTLINE OF DIAGNOSIS
CY: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)
1. OUTLINE OF DIAGNOSIS
CZ: DTC P1574 KEY COMMUNICATION FAILURE
1. OUTLINE OF DIAGNOSIS
DA: DTC P1576 EGI CONTROL MODULE EEPROM
1. OUTLINE OF DIAGNOSIS
DB: DTC P1577 IMM CONTROL MODULE EEPROM
1. OUTLINE OF DIAGNOSIS
DC: DTC P1578 METER FAILURE
1. OUTLINE OF DIAGNOSIS
DD: DTC P1602 CONTROL MODULE PROGRAMMING ERROR
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Exhaust temperature diagnosis
. Idle speed diagnosis
. Final ignition timing diagnosis
DE: DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DF: DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DG: DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
DH: DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
DI: DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
DJ: DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
DK: DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DL: DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DM: DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DN: DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DO: DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DP: DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DQ: DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DR: DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DS: DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DT: DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DU: DTC U0101 CAN (TCU) DATA NOT LOADED
1. OUTLINE OF DIAGNOSIS
DV: DTC U0122 CAN (VDC) DATA NOT LOADED
1. OUTLINE OF DIAGNOSIS
DW: DTC U0140 CAN (BCU) DATA NOT LOADED
1. OUTLINE OF DIAGNOSIS
DX: DTC U0402 CAN (TCU) DATA ABNORMAL
1. OUTLINE OF DIAGNOSIS
DY: DTC U0416 CAN (VDC) DATA ABNORMAL
1. OUTLINE OF DIAGNOSIS
DZ: DTC U0422 CAN (BCU) DATA ABNORMAL
1. OUTLINE OF DIAGNOSIS
ENGINE 2 SECTION
FUEL INJECTION (FUEL SYSTEMS) FU(H4DOTC)
1. General Description
A: SPECIFICATION
B: COMPONENT
1. INTAKE MANIFOLD 1
2. INTAKE MANIFOLD 2
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
4. FUEL TANK
5. FUEL LINE
6. FUEL FILLER PIPE
7. FUEL PUMP
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Throttle Body
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. THROTTLE SENSOR INSPECTION (METHOD WITH CIRCUIT TESTER)
2. THROTTLE SENSOR INSPECTION (METHOD WITH SUBARU SELECT MONITOR)
3. Intake Manifold
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
4. Engine Coolant Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Crankshaft Position Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CRANKSHAFT POSITION SENSOR (METHOD WITH CIRCUIT TESTER)
2. CRANKSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE)
3. OTHER INSPECTIONS
6. Camshaft Position Sensor
A: REMOVAL
1. INTAKE SIDE
. Camshaft position sensor RH
. Camshaft position sensor LH
2. EXHAUST SIDE
B: INSTALLATION
1. INTAKE SIDE
2. EXHAUST SIDE
C: INSPECTION
1. CAMSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE)
2. OTHER INSPECTIONS
7. Knock Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Throttle Position Sensor
A: SPECIFICATION
9. Mass Air Flow and Intake Air Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CHECK MASS AIR FLOW SENSOR UNIT
2. CHECK INTAKE AIR TEMPERATURE SENSOR UNIT
3. OTHER INSPECTIONS
10. Manifold Absolute Pressure Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
11. Fuel Injector
A: REMOVAL
1. RH SIDE
2. LH SIDE
B: INSTALLATION
1. RH SIDE
2. LH SIDE
C: INSPECTION
12. Tumble Generator Valve Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
13. Tumble Generator Valve Actuator
A: SPECIFICATION
14. Oil Flow Control Solenoid Valve
A: REMOVAL
1. INTAKE SIDE
2. EXHAUST SIDE
B: INSTALLATION
1. INTAKE SIDE
2. EXHAUST SIDE
C: DISASSEMBLY
1. INTAKE SIDE
2. EXHAUST SIDE
D: ASSEMBLY
1. INTAKE SIDE
2. EXHAUST SIDE
E: INSPECTION
15. Wastegate Control Solenoid Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
16. Front Oxygen (A/F) Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
17. Rear Oxygen Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
18. Engine Control Module (ECM)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
19. Main Relay
A: REMOVAL
B: INSTALLATION
C: INSPECTION
20. Fuel Pump Relay
A: REMOVAL
B: INSTALLATION
C: INSPECTION
21. Electronic Throttle Control Relay
A: REMOVAL
B: INSTALLATION
C: INSPECTION
22. Fuel Pump Control Unit
A: REMOVAL
B: INSTALLATION
C: INSPECTION
23. Fuel
A: PROCEDURE
1. RELEASING OF FUEL PRESSURE
2. DRAINING FUEL (WITH SUBARU SELECT MONITOR)
3. DRAINING FUEL (THROUGH THE FUEL FILLER HOSE)
24. Fuel Tank
A: REMOVAL
B: INSTALLATION
C: INSPECTION
25. Fuel Filler Pipe
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
26. Fuel Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
27. Fuel Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
28. Fuel Sub Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
29. Fuel Filter
A: REMOVAL
B: INSTALLATION
30. Fuel Damper
A: REMOVAL
B: INSTALLATION
C: INSPECTION
31. Fuel Delivery, Return and Evaporation Lines
A: REMOVAL
B: INSTALLATION
1. INSTALLATION OF EVAPORATION PIPE
2. CONNECTING THE FUEL LINE QUICK CONNECTOR
3. CONNECT FUEL DELIVERY HOSE AND FUEL RETURN HOSE.
4. EVAPORATION HOSE CONNECTION
5. CONNECTING THE EVAPORATION LINE QUICK CONNECTOR
C: INSPECTION
32. Fuel System Trouble in General
A: INSPECTION
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H4DOTC)
1. General Description
A: CAUTION
B: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Front Catalytic Converter
A: REMOVAL
B: INSTALLATION
C: INSPECTION
3. Rear Catalytic Converter
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Canister
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Purge Control Solenoid Valve
A: REMOVAL
1. PURGE CONTROL SOLENOID VALVE 1
2. PURGE CONTROL SOLENOID VALVE 2
B: INSTALLATION
1. PURGE CONTROL SOLENOID VALVE 1
2. PURGE CONTROL SOLENOID VALVE 2
C: INSPECTION
1. PURGE CONTROL SOLENOID VALVE
2. OTHER INSPECTIONS
6. Fuel Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Fuel Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Fuel Sub Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
9. Fuel Tank Pressure Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. FUEL TANK PRESSURE SENSOR
2. OTHER INSPECTIONS
10. Pressure Control Solenoid Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. PRESSURE CONTROL SOLENOID VALVE
2. OTHER INSPECTIONS
11. Drain Filter
A: SPECIFICATION
12. Shut Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
13. Drain Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
14. PCV Hose Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
15. PCV Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. PCV VALVE
2. OTHER INSPECTIONS
INTAKE (INDUCTION) IN(H4DOTC)
1. General Description
A: COMPONENT
1. AIR CLEANER
2. INTAKE DUCT
3. INTERCOOLER
4. TURBOCHARGER
B: CAUTION
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Air Cleaner Element
A: REMOVAL
B: INSTALLATION
C: INSPECTION
3. Air Cleaner Case
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Air Intake Boot
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
5. Air Intake Duct
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Intake Duct
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
7. Intercooler
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Turbocharger
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. WASTE GATE ACTUATOR
2. OTHER INSPECTIONS
9. Oil Catch Tank
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Scavenge Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
11. Air By-pass Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. AIR BY-PASS VALVE
2. OTHER INSPECTIONS
12. Resonator Chamber
A: REMOVAL
B: INSTALLATION
C: INSPECTION
MECHANICAL ME(H4DOTC)
1. General Description
A: SPECIFICATION
B: COMPONENT
1. V-BELT
2. TIMING BELT
3. CYLINDER HEAD AND CAMSHAFT
4. CYLINDER HEAD AND VALVE ASSEMBLY
5. CYLINDER BLOCK
6. CRANKSHAFT AND PISTON
7. ENGINE MOUNTING
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Compression
A: INSPECTION
3. Idle Speed
A: INSPECTION
4. Ignition Timing
A: INSPECTION
1. METHOD WITH SUBARU SELECT MONITOR
2. METHOD WITH TIMING LIGHT
5. Intake Manifold Vacuum
A: INSPECTION
6. Engine Oil Pressure
A: INSPECTION
7. Fuel Pressure
A: INSPECTION
8. Valve Clearance
A: INSPECTION
B: ADJUSTMENT
9. Engine Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Engine Mounting
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
11. Preparation for Overhaul
A: PROCEDURE
12. V-belt
A: REMOVAL
1. V-BELT
2. V-BELT TENSIONER ASSEMBLY AND IDLER PULLEY
B: INSTALLATION
1. V-BELT
2. V-BELT TENSIONER ASSEMBLY AND IDLER PULLEY
C: INSPECTION
13. Crank Pulley
A: REMOVAL
B: INSTALLATION
1. METHOD WITHOUT ANGLE GAUGE
2. METHOD WITH ANGLE GAUGE
C: INSPECTION
14. Timing Belt Cover
A: REMOVAL
1. WORK ON THE VEHICLE
2. WORK ON THE ENGINE UNIT ONLY
B: INSTALLATION
1. WORK ON THE VEHICLE
2. WORK ON THE ENGINE UNIT ONLY
C: INSPECTION
15. Timing Belt
A: REMOVAL
1. TIMING BELT
2. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
2. TIMING BELT
C: INSPECTION
1. TIMING BELT
2. AUTOMATIC BELT TENSION ADJUSTER
3. BELT TENSION PULLEY
4. BELT IDLER
16. Cam Sprocket
A: REMOVAL
B: INSTALLATION
C: INSPECTION
17. Crank Sprocket
A: REMOVAL
B: INSTALLATION
C: INSPECTION
18. Camshaft
A: REMOVAL
B: INSTALLATION
C: INSPECTION
19. Cylinder Head
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. CYLINDER HEAD
2. VALVE SEAT
3. VALVE GUIDE
4. INTAKE AND EXHAUST VALVE
5. VALVE SPRING
6. INTAKE AND EXHAUST VALVE OIL SEAL
7. VALVE LIFTER
20. Cylinder Block
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. CYLINDER BLOCK
2. CYLINDER AND PISTON
3. PISTON AND PISTON PIN
4. PISTON RING
5. CONNECTING ROD
6. CRANKSHAFT AND CRANKSHAFT BEARING
21. Intake and Exhaust Valve
A: SPECIFICATION
22. Piston
A: SPECIFICATION
23. Connecting Rod
A: SPECIFICATION
24. Crankshaft
A: SPECIFICATION
25. Engine Trouble in General
A: INSPECTION
26. Engine Noise
A: INSPECTION
EXHAUST EX(H4DOTC)
1. General Description
A: COMPONENT
1. FRONT EXHAUST PIPE
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER
B: CAUTION
C: PREPARATION TOOL
1. GENERAL TOOL
2. Front Exhaust Pipe
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
3. Center Exhaust Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Rear Exhaust Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Muffler
A: REMOVAL
B: INSTALLATION
C: INSPECTION
COOLING CO(H4DOTC)
1. General Description
A: SPECIFICATION
B: COMPONENT
1. WATER PUMP
2. RADIATOR AND RADIATOR FAN
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Radiator Fan System
A: WIRING DIAGRAM
B: INSPECTION
3. Engine Coolant
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
2. FILLING OF ENGINE COOLANT
B: ADJUSTMENT
1. PROCEDURE TO ADJUST THE SUBARU SUPER COOLANT CONCENTRATION
4. Water Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Thermostat
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Radiator
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Radiator Cap
A: INSPECTION
8. Radiator Main Fan and Fan Motor
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
9. Radiator Sub Fan and Fan Motor
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
10. Reservoir Tank
A: REMOVAL
B: INSTALLATION
C: INSPECTION
11. Engine Cooling System Trouble in General
A: INSPECTION
LUBRICATION LU(H4DOTC)
1. General Description
A: SPECIFICATION
SPEED CONTROL SYSTEMS SP(H4DOTC)
1. General Description
A: SPECIFICATION
IGNITION IG(H4DOTC)
1. General Description
A: SPECIFICATION
B: COMPONENT
C: CAUTION
2. Spark Plug
A: REMOVAL
1. RH SIDE
2. LH SIDE
B: INSTALLATION
1. RH SIDE
2. LH SIDE
C: INSPECTION
3. Ignition Coil
A: REMOVAL
B: INSTALLATION
C: INSPECTION
STARTING/CHARGING SYSTEMS SC(H4DOTC)
1. General Description
A: SPECIFICATION
ENGINE (DIAGNOSTICS) EN(H4DOTC)(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
1. ENGINE
2. Check List for Interview
A: CHECK
1. CHECK LIST NO. 1
2. CHECK LIST NO. 2
3. General Description
A: CAUTION
B: INSPECTION
1. BATTERY
2. ENGINE GROUND
C: NOTE
D: PREPARATION TOOL
4. Electrical Component Location
A: LOCATION
1. CONTROL MODULE
2. SENSOR
3. SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS
4. TRANSMISSION
5. Engine Control Module (ECM) I/O Signal
A: ELECTRICAL SPECIFICATION
6. Engine Condition Data
A: ELECTRICAL SPECIFICATION
7. Data Link Connector
A: NOTE
8. General Scan Tool
A: OPERATION
1. HOW TO USE GENERAL SCAN TOOL
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)
4. MODE $03 (EMISSION-RELATED POWERTRAIN DTC)
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
6. MODE $06
7. MODE $07
8. MODE $09
9. Subaru Select Monitor
A: OPERATION
1. HOW TO USE THE SUBARU SELECT MONITOR
2. READ CURRENT DATA FOR ENGINE (NORMAL MODE)
3. READ CURRENT DATA FOR ENGINE (OBD MODE)
4. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE)
5. V.I.N. REGISTRATION
10. Read Diagnostic Trouble Code (DTC)
A: OPERATION
1. SUBARU SELECT MONITOR
2. GENERAL SCAN TOOL
11. Inspection Mode
A: PROCEDURE
1. PREPARATION FOR THE INSPECTION MODE
2. SUBARU SELECT MONITOR
3. GENERAL SCAN TOOL
12. Drive Cycle
A: PROCEDURE
1. PREPARATION FOR DRIVE CYCLE
2. DRIVE CYCLE A
3. DRIVE CYCLE B
4. DRIVE CYCLE C
5. DRIVE CYCLE D
DRIFT DIAGNOSIS
STUCK DIAGNOSIS
6. DRIVE CYCLE E
7. DRIVE CYCLE F
8. DRIVE CYCLE H
13. Clear Memory Mode
A: OPERATION
1. SUBARU SELECT MONITOR
2. GENERAL SCAN TOOL
14. System Operation Check Mode
A: OPERATION
15. Malfunction Indicator Light
A: PROCEDURE
B: ACTIVATION OF MALFUNCTION INDICATOR LIGHT
C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON
D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF
E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK
F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING
16. Diagnostics for Engine Starting Failure
A: PROCEDURE
B: STARTER MOTOR CIRCUIT
C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM)
D: IGNITION CONTROL SYSTEM
E: FUEL PUMP CIRCUIT
F: FUEL INJECTOR CIRCUIT
17. List of Diagnostic Trouble Code (DTC)
A: LIST
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1)
B: DTC P0014 EXHAUST AVCS SYSTEM 1 (RANGE/PERFORMANCE)
C: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1)
D: DTC P0017 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 1)
E: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2)
F: DTC P0019 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 2)
G: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2)
H: DTC P0024 EXHAUST AVCS SYSTEM 2 (RANGE/PERFORMANCE)
I: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
J: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)
K: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)
L: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
M: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
N: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
O: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE
P: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT
Q: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
R: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT
S: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT
T: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE
U: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
V: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
W: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
X: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
Y: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW
Z: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH
AA: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
AB: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION
AC: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
AD: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
AE: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
AF: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
AG: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)
AH: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)
AI: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
AJ: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
AK: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)
AL: DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2)
AM: DTC P0171 SYSTEM TOO LEAN (BANK 1)
AN: DTC P0172 SYSTEM TOO RICH (BANK 1)
AO: DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE
AP: DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT
AQ: DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT
AR: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW
AS: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH
AT: DTC P0230 FUEL PUMP PRIMARY CIRCUIT
AU: DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” RANGE/PERFORMANCE
AV: DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” LOW
AW: DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” HIGH
AX: DTC P0301 CYLINDER 1 MISFIRE DETECTED
AY: DTC P0302 CYLINDER 2 MISFIRE DETECTED
AZ: DTC P0303 CYLINDER 3 MISFIRE DETECTED
BA: DTC P0304 CYLINDER 4 MISFIRE DETECTED
BB: DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)
BC: DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)
BD: DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT
BE: DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE
BF: DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR)
BG: DTC P0345 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 2)
BH: DTC P0365 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 1)
BI: DTC P0390 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 2)
BJ: DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)
BK: DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
BL: DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
BM: DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
BN: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR
BO: DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
BP: DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
BQ: DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
BR: DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
BS: DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
BT: DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
BU: DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE
BV: DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW
BW: DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH
BX: DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
BY: DTC P0500 VEHICLE SPEED SENSOR “A”
BZ: DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
CA: DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
CB: DTC P0512 STARTER REQUEST CIRCUIT
CC: DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
CD: DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
CE: DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE
CF: DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)
CG: DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)
CH: DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)
CI: DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)
CJ: DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)
CK: DTC P1160 RETURN SPRING FAILURE
CL: DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW
CM: DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
CN: DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
CO: DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT
CP: DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
CQ: DTC P1602 CONTROL MODULE PROGRAMMING ERROR
CR: DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1)
CS: DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2)
CT: DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1)
CU: DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2)
CV: DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1)
CW: DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1)
CX: DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2)
CY: DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2)
CZ: DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1)
DA: DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1)
DB: DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2)
DC: DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2)
DD: DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
DE: DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
DF: DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
DG: DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
DH: DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
DI: DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
DJ: DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
DK: DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
DL: DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
DM: DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
DN: DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE
DO: DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
DP: DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
DQ: DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP PERFORMANCE
DR: DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT
DS: DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT
DT: DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT
DU: DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT
DV: DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION
DW: DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION
DX: DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE
DY: DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW
DZ: DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH
EA: DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW
EB: DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH
EC: DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION
ED: DTC U0101 CAN (TCU) DATA NOT LOADED
EE: DTC U0122 CAN (VDC) DATA NOT LOADED
EF: DTC U0140 CAN (BCU) DATA NOT LOADED
EG: DTC U0402 CAN (TCU) DATA ABNORMAL
EH: DTC U0416 CAN (VDC) DATA ABNORMAL
EI: DTC U0422 CAN (BCU) DATA ABNORMAL
19. General Diagnostic Table
A: INSPECTION
1. ENGINE
GENERAL DESCRIPTION GD(H4DOTC)
1. List of Diagnostic Trouble Code (DTC)
A: LIST
2. Diagnostic Trouble Code (DTC) Detecting Criteria
A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
B: DTC P0014 EXHAUST AVCS SYSTEM 1 (RANGE/PERFORMANCE)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
C: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
D: DTC P0017 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
E: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2)
1. OUTLINE OF DIAGNOSIS
F: DTC P0019 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 2)
1. OUTLINE OF DIAGNOSIS
G: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2)
1. OUTLINE OF DIAGNOSIS
H: DTC P0024 EXHAUST AVCS SYSTEM 2 (RANGE/PERFORMANCE)
1. OUTLINE OF DIAGNOSIS
I: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
J: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
K: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
L: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
M: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
N: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
O: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
P: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
Q: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
R: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
S: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
T: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
U: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
V: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
W: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
X: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
Y: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
Z: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AA: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AB: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AC: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AD: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AE: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AF: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AG: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AH: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AI: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
AJ: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
Diagnostic method
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
6. ENABLE CONDITION
7. GENERAL DRIVING CYCLE
8. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AK: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION (USED ONLY FOR MALFUNCTION JUDGMENT)
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AL: DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AM: DTC P0171 SYSTEM TOO LEAN (BANK 1)
1. OUTLINE OF DIAGNOSIS
DIAGNOSTIC METHOD
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AN: DTC P0172 SYSTEM TOO RICH (BANK 1)
1. OUTLINE OF DIAGNOSIS
Diagnostic method
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AO: DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
Drift Diagnosis
Stuck Diagnosis
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
DRIFT DIAGNOSIS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
6. ENABLE CONDITION
Stuck Diagnosis
7. GENERAL DRIVING CYCLE
8. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AP: DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AQ: DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AR: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AS: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AT: DTC P0230 FUEL PUMP PRIMARY CIRCUIT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AU: DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AV: DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
Abnormality Judgment
Normality Judgment
AW: DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
Abnormality Judgment
Normality Judgment
AX: DTC P0301 CYLINDER 1 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
180˚ Interval Difference Method
360˚ Interval Difference Method
720˚ Interval Difference Method
. FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas)
. Catalyst damage misfire (Misfire occurrence level damaging catalyst)
AY: DTC P0302 CYLINDER 2 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
AZ: DTC P0303 CYLINDER 3 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
BA: DTC P0304 CYLINDER 4 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
BB: DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BC: DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BD: DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BE: DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BF: DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment 1
. Normality Judgment 1
. Abnormality Judgment 2
. Normality Judgment 2
BG: DTC P0345 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 2)
1. OUTLINE OF DIAGNOSIS
BH: DTC P0365 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BI: DTC P0390 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 2)
1. OUTLINE OF DIAGNOSIS
BJ: DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BK: DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
1. OUTLINE OF DIAGNOSIS
0.04-inch Diagnosis
Mode Table for Evaporative Emission Control System Diagnosis
0.02-inch Diagnosis
2. COMPONENT DESCRIPTION
Pressure control solenoid valve
Valve Operation and Air Flow
Drain valve
3. ENABLE CONDITION
0.04-inch Diagnosis
0.02-inch Diagnosis
4. GENERAL DRIVING CYCLE
0.04-inch Diagnosis
0.02-inch Diagnosis
5. DIAGNOSTIC METHOD
Purge control solenoid valve stuck open fault diagnosis
Purge control solenoid valve Open Fixation
Leak Diagnosis
Leak Diagnosis
BL: DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BM: DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BN: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BO: DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BP: DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BQ: DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
1. OUTLINE OF DIAGNOSIS
BR: DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
1. OUTLINE OF DIAGNOSIS
BS: DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BT: DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BU: DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BV: DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BW: DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BX: DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BY: DTC P0500 VEHICLE SPEED SENSOR “A”
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BZ: DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CA: DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CB: DTC P0512 STARTER REQUEST CIRCUIT
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CC: DTC P0513 INCORRECT IMMOBILIZER KEY
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
CD: DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CE: DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
Abnormality Judgment
CF: DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
CG: DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
CH: DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CI: DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CJ: DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CK: DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CL: DTC P1160 RETURN SPRING FAILURE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CM: DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CN: DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CO: DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CP: DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITIONS
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CQ: DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CR: DTC P1570 ANTENNA
1. OUTLINE OF DIAGNOSIS
CS: DTC P1571 REFERENCE CODE INCOMPATIBILITY
1. OUTLINE OF DIAGNOSIS
CT: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)
1. OUTLINE OF DIAGNOSIS
CU: DTC P1574 KEY COMMUNICATION FAILURE
1. OUTLINE OF DIAGNOSIS
CV: DTC P1576 EGI CONTROL MODULE EEPROM
1. OUTLINE OF DIAGNOSIS
CW: DTC P1577 IMM CONTROL MODULE EEPROM
1. OUTLINE OF DIAGNOSIS
CX: DTC P1578 METER FAILURE
1. OUTLINE OF DIAGNOSIS
CY: DTC P1602 CONTROL MODULE PROGRAMMING ERROR
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Exhaust temperature diagnosis
. Idle speed diagnosis
. Final ignition timing diagnosis
CZ: DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DA: DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DB: DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DC: DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DD: DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DE: DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DF: DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DG: DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DH: DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DI: DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DJ: DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DK: DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DL: DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DM: DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DN: DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITIONS
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DO: DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITIONS
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DP: DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
1. OUTLINE OF DIAGNOSIS
DQ: DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
1. OUTLINE OF DIAGNOSIS
DR: DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
1. OUTLINE OF DIAGNOSIS
DS: DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
1. OUTLINE OF DIAGNOSIS
DT: DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DU: DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DV: DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DW: DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DX: DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DY: DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DZ: DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EA: DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EB: DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EC: DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
ED: DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EE: DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EF: DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EG: DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EH: DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EI: DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITIONS
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EJ: DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITIONS
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EK: DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EL: DTC U0101 CAN (TCU) DATA NOT LOADED
1. OUTLINE OF DIAGNOSIS
EM: DTC U0122 CAN (VDC) DATA NOT LOADED
1. OUTLINE OF DIAGNOSIS
EN: DTC U0140 CAN (BCU) DATA NOT LOADED
1. OUTLINE OF DIAGNOSIS
EO: DTC U0402 CAN (TCU) DATA ABNORMAL
1. OUTLINE OF DIAGNOSIS
EP: DTC U0416 CAN (VDC) DATA ABNORMAL
1. OUTLINE OF DIAGNOSIS
EQ: DTC U0422 CAN (BCU) DATA ABNORMAL
1. OUTLINE OF DIAGNOSIS
ENGINE 3 SECTION
FUEL INJECTION (FUEL SYSTEMS) FU(H6DO)
1. General Description
A: SPECIFICATION
B: COMPONENT
1. INTAKE MANIFOLD
2. FUEL INJECTOR
3. AIR INTAKE SYSTEM
4. SENSOR
5. ENGINE HARNESS
Engine harness assembly diagram 1
Engine harness assembly diagram 2
6. FUEL TANK
7. FUEL LINE
8. FUEL FILLER PIPE
9. FUEL PUMP
C: CAUTION
D: PREPARATION TOOL
1. ST
2. GENERAL TOOL
2. Throttle Body
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. THROTTLE SENSOR (METHOD WITH CIRCUIT TESTER)
2. THROTTLE SENSOR (METHOD WITH SUBARU SELECT MONITOR)
3. OTHER INSPECTIONS
3. Intake Manifold
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
4. Engine Coolant Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Crankshaft Position Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CRANKSHAFT POSITION SENSOR (METHOD WITH CIRCUIT TESTER)
2. CRANKSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE)
3. OTHER INSPECTIONS
6. Camshaft Position Sensor
A: REMOVAL
1. INTAKE SIDE
2. EXHAUST SIDE
B: INSTALLATION
1. INTAKE SIDE
2. EXHAUST SIDE
C: INSPECTION
1. CAMSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE)
2. OTHER INSPECTIONS
7. Knock Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Throttle Position Sensor
A: SPECIFICATION
9. Manifold Absolute Pressure Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Mass Air Flow and Intake Air Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CHECK MASS AIR FLOW SENSOR UNIT
2. CHECK INTAKE AIR TEMPERATURE SENSOR UNIT
3. OTHER INSPECTIONS
11. EGR Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
12. Fuel Injector
A: REMOVAL
1. RH SIDE
2. LH SIDE
B: INSTALLATION
1. RH SIDE
2. LH SIDE
13. Oil Flow Control Solenoid Valve
A: REMOVAL
1. INTAKE SIDE
2. EXHAUST SIDE
B: INSTALLATION
1. INTAKE SIDE
2. EXHAUST SIDE
C: INSPECTION
14. Oil Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
15. Front Oxygen (A/F) Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
16. Rear Oxygen Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
17. Engine Control Module (ECM)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
18. Main Relay
A: REMOVAL
B: INSTALLATION
C: INSPECTION
19. Fuel Pump Relay
A: REMOVAL
B: INSTALLATION
C: INSPECTION
20. Electronic Throttle Control Relay
A: REMOVAL
B: INSTALLATION
C: INSPECTION
21. Fuel Pump Control Unit
A: REMOVAL
B: INSTALLATION
C: INSPECTION
22. Fuel
A: PROCEDURE
1. RELEASING OF FUEL PRESSURE
2. DRAINING FUEL (WITH SUBARU SELECT MONITOR)
3. DRAINING FUEL (THROUGH THE FUEL FILLER HOSE)
23. Fuel Tank
A: REMOVAL
B: INSTALLATION
C: INSPECTION
24. Fuel Filler Pipe
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
25. Fuel Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
26. Fuel Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
27. Fuel Sub Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
28. Fuel Filter
A: REMOVAL
B: INSTALLATION
29. Fuel Damper
A: REMOVAL
B: INSTALLATION
C: INSPECTION
30. Fuel Delivery and Evaporation Lines
A: REMOVAL
B: INSTALLATION
1. INSTALLATION OF EVAPORATION PIPE
2. CONNECTING THE FUEL LINE QUICK CONNECTOR
3. CONNECTING THE FUEL DELIVERY HOSE
4. EVAPORATION HOSE CONNECTION
5. CONNECTING THE EVAPORATION LINE QUICK CONNECTOR
C: INSPECTION
31. Fuel System Trouble in General
A: INSPECTION
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H6DO)
1. General Description
A: CAUTION
B: PREPARATION TOOL
1. GENERAL TOOL
2. Front Catalytic Converter
A: REMOVAL
B: INSTALLATION
C: INSPECTION
3. Rear Catalytic Converter
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. EGR Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Canister
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Purge Control Solenoid Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. PURGE CONTROL SOLENOID VALVE
2. OTHER INSPECTIONS
7. Fuel Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Fuel Temperature Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
9. Fuel Sub Level Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Fuel Tank Pressure Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. FUEL TANK PRESSURE SENSOR
2. OTHER INSPECTIONS
11. Drain Filter
A: SPECIFICATION
12. Drain Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
13. PCV Valve
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. PCV VALVE
2. OTHER INSPECTIONS
INTAKE (INDUCTION) IN(H6DO)
1. General Description
A: COMPONENT
B: CAUTION
2. Air Cleaner Element
A: REMOVAL
B: INSTALLATION
C: INSPECTION
3. Air Cleaner Case
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Air Intake Boot
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Air Intake Duct
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Resonator Chamber
A: REMOVAL
B: INSTALLATION
C: INSPECTION
MECHANICAL ME(H6DO)
1. General Description
A: SPECIFICATION
B: COMPONENT
1. V-BELT
2. CHAIN COVER
3. TIMING CHAIN
4. CYLINDER HEAD AND CAMSHAFT
5. CYLINDER HEAD AND VALVE ASSEMBLY
6. CYLINDER BLOCK
7. CRANKSHAFT AND PISTON
8. ENGINE HARNESS
Engine harness assembly diagram 1
Engine harness assembly diagram 2
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
E: PROCEDURE
2. Compression
A: INSPECTION
3. Idle Speed
A: INSPECTION
4. Ignition Timing
A: INSPECTION
1. METHOD WITH SUBARU SELECT MONITOR
2. METHOD WITH TIMING LIGHT
5. Intake Manifold Vacuum
A: INSPECTION
6. Engine Oil Pressure
A: INSPECTION
7. Fuel Pressure
A: INSPECTION
8. Valve Clearance
A: INSPECTION
B: ADJUSTMENT
1. INTAKE SIDE
2. EXHAUST SIDE
9. Engine Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Engine Mounting
A: REMOVAL
B: INSTALLATION
C: INSPECTION
11. Preparation for Overhaul
A: REMOVAL
12. V-belt
A: REMOVAL
B: INSTALLATION
C: INSPECTION
13. Crank Pulley
A: REMOVAL
B: INSTALLATION
C: INSPECTION
14. Chain Cover
A: REMOVAL
B: INSTALLATION
C: INSPECTION
15. Timing Chain Assembly
A: LOCATION
B: REMOVAL
C: INSTALLATION
16. Cam Sprocket
A: REMOVAL
B: INSTALLATION
C: INSPECTION
17. Crank Sprocket
A: REMOVAL
B: INSTALLATION
C: INSPECTION
18. Camshaft
A: REMOVAL
B: INSTALLATION
C: INSPECTION
19. Cylinder Head
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. CYLINDER HEAD
2. VALVE SEAT
3. VALVE GUIDE
4. INTAKE AND EXHAUST VALVE
5. VALVE SPRING
6. INTAKE AND EXHAUST VALVE OIL SEAL
7. VALVE LIFTER
20. Cylinder Block
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. CYLINDER BLOCK
2. CYLINDER AND PISTON
3. PISTON AND PISTON PIN
4. PISTON RING
5. CONNECTING ROD
6. CRANKSHAFT AND CRANKSHAFT BEARING
21. Oil Flow Control Solenoid Valve
A: REMOVAL
B: INSTALLATION
22. Intake and Exhaust Valve
A: SPECIFICATION
23. Piston
A: SPECIFICATION
24. Connecting Rod
A: SPECIFICATION
25. Crankshaft
A: SPECIFICATION
26. Engine Trouble in General
A: INSPECTION
27. Engine Noise
A: INSPECTION
EXHAUST EX(H6DO)
1. General Description
A: COMPONENT
1. FRONT EXHAUST PIPE
2. REAR EXHAUST PIPE AND MUFFLER
B: CAUTION
2. Front Exhaust Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
3. Rear Exhaust Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Muffler
A: REMOVAL
B: INSTALLATION
C: INSPECTION
COOLING CO(H6DO)
1. General Description
A: SPECIFICATION
B: COMPONENT
1. WATER PUMP AND WATER PIPE
2. ENGINE COOLANT TEMPERATURE SENSOR AND HEATER HOSE
3. RADIATOR AND RADIATOR FAN
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Radiator Fan System
A: WIRING DIAGRAM
B: RADIATOR FAN CONTROL OUTPUT WAVEFORM
C: INSPECTION
3. Engine Coolant
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
2. FILLING OF ENGINE COOLANT
B: ADJUSTMENT
1. PROCEDURE TO ADJUST THE SUBARU SUPER COOLANT CONCENTRATION
4. Water Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Thermostat
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Radiator
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Radiator Cap
A: INSPECTION
8. Radiator Main Fan and Fan Motor
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
9. Radiator Sub Fan and Fan Motor
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
10. Reservoir Tank
A: REMOVAL
B: INSTALLATION
C: INSPECTION
11. Radiator Fan Control Unit
A: REMOVAL
B: INSTALLATION
12. Engine Cooling System Trouble in General
A: INSPECTION
LUBRICATION LU(H6DO)
1. General Description
A: SPECIFICATION
B: COMPONENT
1. OIL PAN UPPER, OIL COOLER, AND OIL FILTER
2. OIL PUMP
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Oil Pressure System
A: WIRING DIAGRAM
B: INSPECTION
3. Engine Oil
A: INSPECTION
B: REPLACEMENT
4. Oil Pan
A: REMOVAL
B: INSTALLATION
C: INSPECTION
5. Oil Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Oil Pressure Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Engine Oil Filter
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Oil Cooler
A: REMOVAL
B: INSTALLATION
C: INSPECTION
9. Oil Level Switch
A: REMOVAL
B: INSTALLATION
C: WIRING DIAGRAM
D: INSPECTION
1. INSPECTION WHILE OIL LEVEL SWITCH WARNING LIGHT IS ON
2. OTHER INSPECTIONS
10. Engine Lubrication System Trouble in General
A: INSPECTION
SPEED CONTROL SYSTEMS SP(H6DO)
1. General Description
A: SPECIFICATION
IGNITION IG(H6DO)
1. General Description
A: SPECIFICATION
B: COMPONENT
C: CAUTION
2. Spark Plug
A: REMOVAL
1. RH SIDE
2. LH SIDE
B: INSTALLATION
1. RH SIDE
2. LH SIDE
C: INSPECTION
3. Ignition Coil
A: REMOVAL
B: INSTALLATION
C: INSPECTION
STARTING/CHARGING SYSTEMS SC(H6DO)
1. General Description
A: SPECIFICATION
ENGINE (DIAGNOSTICS) EN(H6DO)(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
1. ENGINE
2. Check List for Interview
A: CHECK
1. CHECK LIST NO. 1
2. CHECK LIST NO. 2
3. General Description
A: CAUTION
B: INSPECTION
1. BATTERY
2. ENGINE GROUND
C: NOTE
D: PREPARATION TOOL
4. Electrical Component Location
A: LOCATION
1. CONTROL MODULE
2. SENSOR
3. SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS
5. Engine Control Module (ECM) I/O Signal
A: ELECTRICAL SPECIFICATION
6. Engine Condition Data
A: ELECTRICAL SPECIFICATION
7. Data Link Connector
A: NOTE
8. General Scan Tool
A: OPERATION
1. HOW TO USE GENERAL SCAN TOOL
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)
4. MODE $03 (EMISSION-RELATED POWERTRAIN DTC)
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
6. MODE $06
7. MODE $07
8. MODE $09
9. Subaru Select Monitor
A: OPERATION
1. HOW TO USE THE SUBARU SELECT MONITOR
2. READ CURRENT DATA FOR ENGINE (NORMAL MODE)
3. READ CURRENT DATA FOR ENGINE (OBD MODE)
4. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE)
5. V.I.N. REGISTRATION
10. Read Diagnostic Trouble Code (DTC)
A: OPERATION
1. SUBARU SELECT MONITOR (NORMAL MODE)
2. GENERAL SCAN TOOL
11. Inspection Mode
A: PROCEDURE
1. PREPARATION FOR THE INSPECTION MODE
2. SUBARU SELECT MONITOR
3. GENERAL SCAN TOOL
12. Drive Cycle
A: PROCEDURE
1. PREPARATION FOR DRIVE CYCLE
2. DRIVE CYCLE A
3. DRIVE CYCLE B
4. DRIVE CYCLE C
5. DRIVE CYCLE D
DRIFT DIAGNOSIS
STUCK DIAGNOSIS
6. DRIVE CYCLE E
7. DRIVE CYCLE F
8. DRIVE CYCLE H
13. Clear Memory Mode
A: OPERATION
1. SUBARU SELECT MONITOR
2. GENERAL SCAN TOOL
14. System Operation Check Mode
A: OPERATION
15. Malfunction Indicator Light
A: PROCEDURE
B: ACTIVATION OF MALFUNCTION INDICATOR LIGHT
C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON
D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF
E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK
F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING
16. Diagnostics for Engine Starting Failure
A: PROCEDURE
B: STARTER MOTOR CIRCUIT
C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM)
D: IGNITION CONTROL SYSTEM
E: FUEL PUMP CIRCUIT
F: FUEL INJECTOR CIRCUIT
17. List of Diagnostic Trouble Code (DTC)
A: LIST
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1)
B: DTC P0014 EXHAUST AVCS SYSTEM 1 (RANGE/PERFORMANCE)
C: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1)
D: DTC P0017 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 1)
E: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2)
F: DTC P0019 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 2)
G: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2)
H: DTC P0024 EXHAUST AVCS SYSTEM 2 (RANGE/PERFORMANCE)
I: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
J: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)
K: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)
L: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
M: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
N: DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1)
O: DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1)
P: DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1)
Q: DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2)
R: DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2)
S: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
T: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE
U: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT
V: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
W: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT
X: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT
Y: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE
Z: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
AA: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
AB: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
AC: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
AD: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW
AE: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH
AF: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
AG: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION
AH: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
AI: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
AJ: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
AK: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
AL: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)
AM: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)
AN: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
AO: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
AP: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)
AQ: DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2)
AR: DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1)
AS: DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1)
AT: DTC P0153 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1)
AU: DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1)
AV: DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2)
AW: DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2)
AX: DTC P0159 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 2)
AY: DTC P0160 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK2 SENSOR2)
AZ: DTC P0161 O2 SENSOR HEATER CIRCUIT (BANK2 SENSOR2)
BA: DTC P0171 SYSTEM TOO LEAN (BANK 1)
BB: DTC P0172 SYSTEM TOO RICH (BANK 1)
BC: DTC P0174 SYSTEM TOO LEAN (BANK 2)
BD: DTC P0175 SYSTEM TOO RICH (BANK 2)
BE: DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE
BF: DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT
BG: DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT
BH: DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE
BI: DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW
BJ: DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH
BK: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW
BL: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH
BM: DTC P0230 FUEL PUMP PRIMARY CIRCUIT
BN: DTC P0301 CYLINDER 1 MISFIRE DETECTED
BO: DTC P0302 CYLINDER 2 MISFIRE DETECTED
BP: DTC P0303 CYLINDER 3 MISFIRE DETECTED
BQ: DTC P0304 CYLINDER 4 MISFIRE DETECTED
BR: DTC P0305 CYLINDER 5 MISFIRE DETECTED
BS: DTC P0306 CYLINDER 6 MISFIRE DETECTED
BT: DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)
BU: DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)
BV: DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2)
BW: DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2)
BX: DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT
BY: DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE
BZ: DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR)
CA: DTC P0345 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 2)
CB: DTC P0365 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 1)
CC: DTC P0390 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 2)
CD: DTC P0400 EXHAUST GAS RECIRCULATION FLOW
CE: DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)
CF: DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
CG: DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
CH: DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
CI: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR
CJ: DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
CK: DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
CL: DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
CM: DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
CN: DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
CO: DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
CP: DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE
CQ: DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW
CR: DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH
CS: DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
CT: DTC P0500 VEHICLE SPEED SENSOR “A”
CU: DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
CV: DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
CW: DTC P0512 STARTER REQUEST CIRCUIT
CX: DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
CY: DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
CZ: DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE
DA: DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)
DB: DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
DC: DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)
DD: DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)
DE: DTC P1154 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 2 SENSOR 1)
DF: DTC P1155 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 2 SENSOR 1)
DG: DTC P1160 RETURN SPRING FAILURE
DH: DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
DI: DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT)
DJ: DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT)
DK: DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT)
DL: DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT)
DM: DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT)
DN: DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT)
DO: DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT)
DP: DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT)
DQ: DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT
DR: DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
DS: DTC P1602 CONTROL MODULE PROGRAMMING ERROR
DT: DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
DU: DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
DV: DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
DW: DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
DX: DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
DY: DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
DZ: DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
EA: DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
EB: DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
EC: DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
ED: DTC P2098 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 2
EE: DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2
EF: DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE
EG: DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
EH: DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
EI: DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP PERFORMANCE
EJ: DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT
EK: DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT
EL: DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT
EM: DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT
EN: DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION
EO: DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION
EP: DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE
EQ: DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW
ER: DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH
ES: DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION
ET: DTC U0101 CAN (TCU) DATA NOT LOADED
EU: DTC U0122 CAN (VDC) DATA NOT LOADED
EV: DTC U0140 CAN (BCU) DATA NOT LOADED
EW: DTC U0402 CAN (TCU) DATA ABNORMAL
EX: DTC U0416 CAN (VDC) DATA ABNORMAL
EY: DTC U0422 CAN (BCU) DATA ABNORMAL
19. General Diagnostic Table
A: INSPECTION
GENERAL DESCRIPTION GD(H6DO)
1. List of Diagnostic Trouble Code (DTC)
A: LIST
2. Diagnostic Trouble Code (DTC) Detecting Criteria
A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
B: DTC P0014 EXHAUST AVCS SYSTEM 1 (RANGE/PERFORMANCE)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
C: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
D: DTC P0017 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
E: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2)
1. OUTLINE OF DIAGNOSIS
F: DTC P0019 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 2)
1. OUTLINE OF DIAGNOSIS
G: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2)
1. OUTLINE OF DIAGNOSIS
H: DTC P0024 EXHAUST AVCS SYSTEM 2 (RANGE/PERFORMANCE)
1. OUTLINE OF DIAGNOSIS
I: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
J: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
K: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
L: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
M: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
N: DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
O: DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
P: DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
Q: DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
R: DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
S: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
T: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
U: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
V: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
W: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
X: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
Y: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
Z: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AA: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AB: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AC: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AD: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AE: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AF: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AG: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AH: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AI: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AJ: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AK: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AL: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AM: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AN: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
AO: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
Diagnostic method
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
6. ENABLE CONDITION
7. GENERAL DRIVING CYCLE
8. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AP: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION (USED ONLY FOR MALFUNCTION JUDGMENT)
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AQ: DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
AR: DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
AS: DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
AT: DTC P0153 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
AU: DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
AV: DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
AW: DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
AX: DTC P0159 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 2)
1. OUTLINE OF DIAGNOSIS
AY: DTC P0160 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK2 SENSOR2)
1. OUTLINE OF DIAGNOSIS
AZ: DTC P0161 O2 SENSOR HEATER CIRCUIT (BANK2 SENSOR2)
1. OUTLINE OF DIAGNOSIS
BA: DTC P0171 SYSTEM TOO LEAN (BANK 1)
1. OUTLINE OF DIAGNOSIS
Diagnostic method
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BB: DTC P0172 SYSTEM TOO RICH (BANK 1)
1. OUTLINE OF DIAGNOSIS
Diagnostic method
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BC: DTC P0174 SYSTEM TOO LEAN (BANK 2)
1. OUTLINE OF DIAGNOSIS
BD: DTC P0175 SYSTEM TOO RICH (BANK 2)
1. OUTLINE OF DIAGNOSIS
BE: DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
Drift Diagnosis
Stuck Diagnosis
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
DRIFT DIAGNOSIS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
6. ENABLE CONDITION
Stuck Diagnosis
7. GENERAL DRIVING CYCLE
8. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BF: DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BG: DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BH: DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BI: DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BJ: DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BK: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BL: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BM: DTC P0230 FUEL PUMP PRIMARY CIRCUIT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BN: DTC P0301 CYLINDER 1 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
120˚ Interval Difference Method
360˚ Interval Difference Method
720˚ Interval Difference Method
. FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas)
. Catalyst damage misfire (Misfire occurrence level damaging catalyst)
BO: DTC P0302 CYLINDER 2 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
BP: DTC P0303 CYLINDER 3 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
BQ: DTC P0304 CYLINDER 4 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
BR: DTC P0305 CYLINDER 5 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
BS: DTC P0306 CYLINDER 6 MISFIRE DETECTED
1. OUTLINE OF DIAGNOSIS
BT: DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BU: DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BV: DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2)
1. OUTLINE OF DIAGNOSIS
BW: DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2)
1. OUTLINE OF DIAGNOSIS
BX: DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BY: DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
BZ: DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment 1
. Normality Judgment 1
. Abnormality Judgment 2
. Normality Judgment 2
CA: DTC P0345 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 2)
1. OUTLINE OF DIAGNOSIS
CB: DTC P0365 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CC: DTC P0390 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 2)
1. OUTLINE OF DIAGNOSIS
CD: DTC P0400 EXHAUST GAS RECIRCULATION FLOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CE: DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CF: DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
1. OUTLINE OF DIAGNOSIS
0.04-inch Diagnosis
Mode Table for Evaporative Emission Control System Diagnosis
0.02-inch Diagnosis
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
0.04-inch Diagnosis
0.02-inch Diagnosis
4. GENERAL DRIVING CYCLE
0.04-inch Diagnosis
0.02-inch Diagnosis
5. DIAGNOSTIC METHOD
Purge control solenoid valve stuck open fault diagnosis
Purge control solenoid valve Open Fixation
Leak Diagnosis
Leak Diagnosis
CG: DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CH: DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CI: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CJ: DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CK: DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CL: DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
1. OUTLINE OF DIAGNOSIS
CM: DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
1. OUTLINE OF DIAGNOSIS
CN: DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CO: DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CP: DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CQ: DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CR: DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CS: DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CT: DTC P0500 VEHICLE SPEED SENSOR “A”
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CU: DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CV: DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CW: DTC P0512 STARTER REQUEST CIRCUIT
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CX: DTC P0513 INCORRECT IMMOBILIZER KEY
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
CY: DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
CZ: DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
Abnormality Judgment
DA: DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
DB: DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
DC: DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DD: DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DE: DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DF: DTC P1154 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 2 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
DG: DTC P1155 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 2 SENSOR 1)
1. OUTLINE OF DIAGNOSIS
DH: DTC P1160 RETURN SPRING FAILURE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DI: DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DJ: DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DK: DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DL: DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT)
1. OUTLINE OF DIAGNOSIS
DM: DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT)
1. OUTLINE OF DIAGNOSIS
DN: DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT)
1. OUTLINE OF DIAGNOSIS
DO: DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT)
1. OUTLINE OF DIAGNOSIS
DP: DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT)
1. OUTLINE OF DIAGNOSIS
DQ: DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT)
1. OUTLINE OF DIAGNOSIS
DR: DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITIONS
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DS: DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
DT: DTC P1570 ANTENNA
1. OUTLINE OF DIAGNOSIS
DU: DTC P1571 REFERENCE CODE INCOMPATIBILITY
1. OUTLINE OF DIAGNOSIS
DV: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)
1. OUTLINE OF DIAGNOSIS
DW: DTC P1574 KEY COMMUNICATION FAILURE
1. OUTLINE OF DIAGNOSIS
DX: DTC P1576 EGI CONTROL MODULE EEPROM
1. OUTLINE OF DIAGNOSIS
DY: DTC P1577 IMM CONTROL MODULE EEPROM
1. OUTLINE OF DIAGNOSIS
DZ: DTC P1578 METER FAILURE
1. OUTLINE OF DIAGNOSIS
EA: DTC P1602 CONTROL MODULE PROGRAMMING ERROR
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Exhaust temperature diagnosis
. Idle speed diagnosis
. Final ignition timing diagnosis
EB: DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EC: DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITION
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
ED: DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITIONS
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EE: DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. ENABLE CONDITIONS
3. GENERAL DRIVING CYCLE
4. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EF: DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
1. OUTLINE OF DIAGNOSIS
EG: DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
1. OUTLINE OF DIAGNOSIS
EH: DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
1. OUTLINE OF DIAGNOSIS
EI: DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
1. OUTLINE OF DIAGNOSIS
EJ: DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EK: DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1)
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EL: DTC P2098 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 2
1. OUTLINE OF DIAGNOSIS
EM: DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2
1. OUTLINE OF DIAGNOSIS
EN: DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EO: DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EP: DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EQ: DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
ER: DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
ES: DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
ET: DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EU: DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EV: DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EW: DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EX: DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EY: DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
EZ: DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITION
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
FA: DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION
1. OUTLINE OF DIAGNOSIS
2. COMPONENT DESCRIPTION
3. ENABLE CONDITIONS
4. GENERAL DRIVING CYCLE
5. DIAGNOSTIC METHOD
. Abnormality Judgment
. Normality Judgment
FB: DTC U0101 CAN (TCU) DATA NOT LOADED
1. OUTLINE OF DIAGNOSIS
FC: DTC U0122 CAN (VDC) DATA NOT LOADED
1. OUTLINE OF DIAGNOSIS
FD: DTC U0140 CAN (BCU) DATA NOT LOADED
1. OUTLINE OF DIAGNOSIS
FE: DTC U0402 CAN (TCU) DATA ABNORMAL
1. OUTLINE OF DIAGNOSIS
FF: DTC U0416 CAN (VDC) DATA ABNORMAL
1. OUTLINE OF DIAGNOSIS
FG: DTC U0422 CAN (BCU) DATA ABNORMAL
1. OUTLINE OF DIAGNOSIS
TRANSMISSION SECTION
CONTROL SYSTEMS CS
1. General Description
A: COMPONENT
1. AT SELECT LEVER
2. 6MT GEAR SHIFT LEVER
B: CAUTION
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. AT Shift Lock Control System
A: LOCATION
B: ELECTRICAL SPECIFICATION
C: WIRING DIAGRAM
D: INSPECTION
1. SHIFT LOCK OPERATION
2. BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT
3. SELECT LEVER CANNOT BE LOCKED OR RELEASED
4. KEY INTERLOCK DOES NOT LOCK OR RELEASE
3. Select Lever
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. GRIP ASSY
2. AT SELECT LEVER ASSEMBLY
3. INDICATOR ASSY
D: ASSEMBLY
E: INSPECTION
4. Select Cable
A: REMOVAL
B: INSTALLATION
C: INSPECTION
D: ADJUSTMENT
5. AT Shift Lock Solenoid and “P” Range Switch
A: REMOVAL
1. SOLENOID UNIT
2. “P” RANGE SWITCH
B: INSTALLATION
C: INSPECTION
6. Body Integrated Unit
A: NOTE
7. MT Gear Shift Lever
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. MT Gear Shift Cable
A: REMOVAL
B: INSTALLATION
9. MT Gear Select Cable
A: REMOVAL
B: INSTALLATION
C: INSPECTION
D: ADJUSTMENT
10. General Diagnostic Table
A: INSPECTION
CONTINUOUSLY VARIABLE TRANSMISSION CVT
1. General Description
A: SPECIFICATION
1. TORQUE CONVERTER
2. OIL PUMP
3. TRANSMISSION CONTROL ELEMENT
4. TRANSMISSION GEAR RATIO
5. PLATE
6. SELECTOR POSITION
7. HYDRAULIC CONTROL AND LUBRICATION
8. COOLING AND HARNESS
9. TRANSFER
10. REDUCTION GEAR RATIO
11. RECOMMENDED GEAR OIL
B: COMPONENT
1. TORQUE CONVERTER ASSEMBLY AND CONVERTER CASE
2. OIL PUMP ASSY
3. TRANSMISSION CASE
4. CONTROL VALVE BODY
5. REVERSE BRAKE ASSEMBLY AND INTERMEDIATE CASE
6. FORWARD CLUTCH ASSEMBLY AND REDUCTION DRIVEN GEAR
7. FRONT REDUCTION DRIVE GEAR AND FRONT REDUCTION DRIVEN GEAR
8. TRANSMISSION CONTROL DEVICE
9. PRIMARY PULLEY, SECONDARY PULLEY AND VARIATOR CHAIN
10. FRONT DIFFERENTIAL GEAR
11. TRANSFER AND EXTENSION CASE
12. TRANSMISSION HARNESS AND SENSOR
13. CVTF COOLER PIPE AND HOSE
14. TRANSMISSION CONTROL MODULE
15. TRANSMISSION MOUNTING
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. CVTF
A: INSPECTION
B: ADJUSTMENT
C: REPLACEMENT
D: CONDITION CHECK
3. Differential Gear Oil
A: ADJUSTMENT
B: REPLACEMENT
4. Variator Chain Break-in
A: GENERAL DESCRIPTION
B: PROCEDURE
5. AWD ON/OFF Switching Mode
A: GENERAL DESCRIPTION
B: PROCEDURE
6. Road Test
A: INSPECTION
1. GENERAL PRECAUTION
2. D RANGE SHIFT FUNCTION
3. KICK-DOWN FUNCTION
4. ENGINE BRAKE OPERATION
5. LOCK-UP FUNCTION
6. P RANGE OPERATION
7. NOISE AND VIBRATION
8. OIL LEAKAGE
7. Stall Test
A: INSPECTION
8. Time Lag Test
A: INSPECTION
9. Secondary Pressure (Line Pressure) Test
A: INSPECTION
10. Transfer Clutch Pressure Test
A: INSPECTION
11. Automatic Transmission Assembly
A: REMOVAL
B: INSTALLATION
12. Transmission Mounting System
A: REMOVAL
B: INSTALLATION
C: INSPECTION
13. Extension Case Oil Seal
A: INSPECTION
B: REPLACEMENT
14. Differential Side Retainer Oil Seal
A: INSPECTION
B: REPLACEMENT
15. Inhibitor Switch
A: INSPECTION
B: ADJUSTMENT
C: REMOVAL
D: INSTALLATION
16. Secondary Speed Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
17. Primary Speed Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
18. Front Wheel Speed Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
19. Secondary Pressure Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
20. Control Valve Body
A: REMOVAL
B: INSTALLATION
C: INSPECTION
21. Transmission Harness
A: REMOVAL
B: INSTALLATION
C: INSPECTION
22. Transmission Control Module (TCM)
A: REMOVAL
B: INSTALLATION
23. CVTF Cooler Pipe and Hose
A: REMOVAL
B: INSTALLATION
C: INSPECTION
24. CVT Oil Cooler
A: REMOVAL
B: INSTALLATION
C: INSPECTION
25. Air Breather Hose
A: REMOVAL
B: INSTALLATION
C: INSPECTION
26. Drive Plate
A: REMOVAL
B: INSTALLATION
C: INSPECTION
27. Preparation for Overhaul
A: GENERAL DESCRIPTION
B: PROCEDURE
28. Torque Converter Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
29. Extension Case
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
30. Rear Drive Shaft
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
31. Transfer Clutch
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
32. Transfer Reduction Driven Gear
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
33. Parking Pawl
A: REMOVAL
B: INSTALLATION
C: INSPECTION
34. Intermediate Case
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
35. CVTF Filter
A: REMOVAL
B: INSTALLATION
C: INSPECTION
36. Reverse Brake Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
37. Forward Clutch Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
38. Reduction Driven Gear
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
39. Transmission Control Device
A: REMOVAL
B: INSTALLATION
C: INSPECTION
40. Transmission Case
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
41. Primary Pulley and Secondary Pulley
A: REMOVAL
B: INSTALLATION
C: INSPECTION
D: ADJUSTMENT
1. PROCEDURE IN REPLACEMENT OF PRIMARY AND SECONDARY PULLEY, OR IN REPLACEMENT OF PRIMARY PULLEY, SECONDARY PULLEY AND VARIATOR CHAIN
2. PROCEDURE WHEN REPLACING ONLY DRIVE PINION RETAINER OR CONVERTER CASE
42. Variator Chain
A: REMOVAL
B: INSTALLATION
C: INSPECTION
43. Drive Pinion Shaft Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
44. Front Differential Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
2. SIDE RETAINER
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSY
2. SIDE RETAINER
E: INSPECTION
F: ADJUSTMENT
45. Oil Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
46. Oil Pump Chain
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. DRIVE SPROCKET
D: ASSEMBLY
1. DRIVE SPROCKET
E: INSPECTION
47. Converter Case Cover
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
48. Front Reduction Drive Gear
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
49. Front Reduction Driven Gear
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
50. Converter Case
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
51. Diagnostics with Phenomenon
A: INSPECTION
CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS) CVT(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. Check List for Interview
A: CHECK
3. General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG”
2. MEASUREMENT
B: INSPECTION
1. BATTERY
2. TRANSMISSION GROUND
3. OPERATION OF SHIFT SELECT LEVER
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
4. Electrical Component Location
A: LOCATION
1. CONTROL MODULE
2. SENSOR
3. SOLENOID
5. Transmission Control Module (TCM) I/O Signal
A: ELECTRICAL SPECIFICATION
B: WAVEFORM
1. SENSOR
2. SOLENOID
6. Subaru Select Monitor
A: OPERATION
7. Read Current Data
A: OPERATION
8. Read Diagnostic Trouble Code (DTC)
A: OPERATION
9. Clear Memory Mode
A: OPERATION
10. Inspection Mode
A: PROCEDURE
11. Learning Control
A: GENERAL DESCRIPTION
B: PROCEDURE
1. PREPARATION FOR LEARNING
2. SIMPLE LEARNING
12. AT OIL TEMP Warning Light Display
A: OPERATION
B: INSPECTION
13. AWD Warning Light Display
A: OPERATION
B: INSPECTION
14. Diagnostic Procedure for Subaru Select Monitor Communication
A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
15. List of Diagnostic Trouble Code (DTC)
A: LIST
16. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
B: DTC P0708 AT RANGE SWITCH NOT INPUTTED
C: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW INPUT
D: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH INPUT
E: DTC P0719 BRAKE SWITCH CIRCUIT LOW
F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT
G: DTC P0724 BRAKE SWITCH CIRCUIT HIGH
H: DTC P0730 GEARSHIFT CONTROL PERFORMANCE ABNORMAL
I: DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT
J: DTC P0841 SECONDARY OIL PRESSURE SENSOR PERFORMANCE
K: DTC P0842 SECONDARY OIL PRESSURE SENSOR CIRCUIT (LOW)
L: DTC P0843 SECONDARY OIL PRESSURE SENSOR CIRCUIT (HIGH)
M: DTC P0890 AT SELF-SHUT RELAY DIAGNOSIS (LOW)
N: DTC P0951 MANUAL SWITCH
O: DTC P0962 SECONDARY SOLENOID CIRCUIT (LOW)
P: DTC P0963 SECONDARY SOLENOID CIRCUIT (HIGH)
Q: DTC P0965 FORWARD & REVERSE SOLENOID FUNCTION
R: DTC P0966 FORWARD & REVERSE SOLENOID CIRCUIT (LOW)
S: DTC P0967 FORWARD & REVERSE LINEAR SOLENOID CIRCUIT (HIGH)
T: DTC P0970 TRANSFER SOLENOID CIRCUIT (LOW)
U: DTC P0971 TRANSFER SOLENOID CIRCUIT (HIGH)
V: DTC P0973 PRIMARY SOLENOID SYSTEM A CIRCUIT (LOW)
W: DTC P0974 PRIMARY SOLENOID SYSTEM A CIRCUIT (HIGH)
X: DTC P0976 PRIMARY SOLENOID SYSTEM B CIRCUIT (LOW)
Y: DTC P0977 PRIMARY SOLENOID SYSTEM B CIRCUIT (HIGH)
Z: DTC P1718 AT CAN COMMUNICATION CIRCUIT
AA: DTC P1724 AT EEPROM ERROR
AB: DTC P1725 AT BODY SYSTEM CAN COMMUNICATION TROUBLE
AC: DTC P2746 PRIMARY PULLEY REVOLUTION SPEED SENSOR CIRCUIT
AD: DTC P2750 SEC. PULLEY REVOLUTION SPEED SENSOR CIRCUIT
AE: DTC P2762 LOCK-UP DUTY SOLENOID MALFUNCTION
AF: DTC P2763 LOCK-UP DUTY SOLENOID CIRCUIT (HIGH)
AG: DTC P2764 LOCK-UP DUTY SOLENOID CIRCUIT (LOW)
AH: DTC P2769 LOCK-UP ON/OFF SOLENOID CIRCUIT (LOW)
AI: DTC P2770 LOCK-UP ON/OFF SOLENOID CIRCUIT (HIGH)
17. Diagnostic Procedure without Diagnostic Trouble Code (DTC)
A: CHECK SHIFT INDICATOR
18. Diagnostics with Phenomenon
A: INSPECTION
AUTOMATIC TRANSMISSION 5AT
1. General Description
A: SPECIFICATION
1. TORQUE CONVERTER CLUTCH
2. OIL PUMP
3. TRANSMISSION CONTROL ELEMENT
4. TRANSMISSION GEAR RATIO
5. PLANETARY GEAR AND PLATE
6. SELECTOR POSITION
7. HYDRAULIC CONTROL AND LUBRICATION
8. COOLING AND HARNESS
9. TRANSFER
10. FINAL REDUCTION GEAR
11. RECOMMENDED GEAR OIL
B: COMPONENT
1. TORQUE CONVERTER CLUTCH & TRANSMISSION ASSEMBLY
2. OIL PUMP & FRONT BRAKE
3. FRONT PLANETARY CARRIER AND MIDDLE & REAR PLANETARY CARRIER
4. DIRECT CLUTCH AND HIGH & LOW REVERSE CLUTCH
5. REVERSE BRAKE
6. SHORT AT ASSEMBLY
7. CONTROL VALVE & TRANSMISSION HARNESS
8. DIFFERENTIAL GEAR
9. TRANSFER CASE, EXTENSION CASE & REDUCTION GEAR
10. TRANSMISSION CONTROL DEVICE & PARKING SUPPORT
11. TRANSMISSION CONTROL MODULE
12. TRANSMISSION MOUNTING
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Automatic Transmission Fluid
A: INSPECTION
B: REPLACEMENT
C: CONDITION CHECK
3. Differential Gear Oil
A: INSPECTION
B: REPLACEMENT
4. Road Test
A: INSPECTION
1. GENERAL PRECAUTION
2. D RANGE SHIFT FUNCTION
3. D RANGE SHIFT SHOCK
4. KICK-DOWN FUNCTION
5. ENGINE BRAKE OPERATION
6. LOCK-UP FUNCTION
7. P RANGE OPERATION
8. NOISE AND VIBRATION
9. OIL LEAKAGE
5. Stall Test
A: INSPECTION
6. Time Lag Test
A: INSPECTION
7. Line Pressure Test
A: MEASUREMENT
8. Transfer Clutch Pressure Test
A: INSPECTION
9. Automatic Transmission Assembly
A: REMOVAL
B: INSTALLATION
10. Transmission Mounting System
A: REMOVAL
1. TRANSMISSION REAR CROSSMEMBER & REAR CUSHION RUBBER
B: INSTALLATION
1. TRANSMISSION REAR CROSSMEMBER & REAR CUSHION RUBBER
C: INSPECTION
1. TRANSMISSION REAR CROSSMEMBER & REAR CUSHION RUBBER
11. Extension Case Oil Seal
A: INSPECTION
B: REPLACEMENT
12. Differential Side Retainer Oil Seal
A: INSPECTION
B: REPLACEMENT
13. Inhibitor Switch
A: INSPECTION
14. Front Vehicle Speed Sensor
A: REMOVAL
B: INSTALLATION
15. Rear Vehicle Speed Sensor
A: REMOVAL
B: INSTALLATION
16. Turbine Speed Sensor 1
A: REMOVAL
B: INSTALLATION
17. Control Valve Body
A: REMOVAL
B: INSTALLATION
C: INSPECTION
18. Transmission Control Module (TCM)
A: REMOVAL
B: INSTALLATION
19. ATF Cooler Pipe and Hose
A: REMOVAL
B: INSTALLATION
C: INSPECTION
20. Air Breather Hose
A: REMOVAL
B: INSTALLATION
C: INSPECTION
21. Oil Charge Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
22. Torque Converter Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
23. Drive Plate
A: REMOVAL
B: INSTALLATION
24. Extension Case
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
25. Transfer Clutch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
D: ADJUSTMENT
1. REAR DRIVE SHAFT SHIM SELECTION
2. SELECTION OF DRIVEN PLATE NO. 3
26. Rear Drive Shaft
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
27. Reduction Driven Gear
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
28. Center Differential Carrier
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
29. Parking Pawl
A: REMOVAL
B: INSTALLATION
C: INSPECTION
30. Converter Case
A: REMOVAL
B: INSTALLATION
C: INSPECTION
31. Oil Pump Cover
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. FRONT BRAKE
2. OIL PUMP
D: ASSEMBLY
1. FRONT BRAKE
2. OIL PUMP
E: INSPECTION
1. FRONT BRAKE
2. OIL PUMP
32. Drive Pinion Shaft Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
33. Front Differential Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
2. SIDE RETAINER
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
2. SIDE RETAINER
E: INSPECTION
F: ADJUSTMENT
34. AT Main Case
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. INPUT CLUTCH PACK ASSEMBLY
D: ASSEMBLY
1. INPUT CLUTCH PACK ASSEMBLY
E: INSPECTION
1. FRONT, MIDDLE & REAR PLANETARY CARRIER ASSEMBLY
2. INPUT CLUTCH
3. HIGH & LOW REVERSE CLUTCH ASSEMBLY
4. DIRECT CLUTCH ASSEMBLY
5. REVERSE BRAKE
F: ADJUSTMENT
35. Transmission Control Device
A: REMOVAL
B: INSTALLATION
C: INSPECTION
36. Diagnostics with Phenomenon
A: INSPECTION
AUTOMATIC TRANSMISSION (DIAGNOSTICS) 5AT(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. Check List for Interview
A: CHECK
3. General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG”
2. MEASUREMENT
B: INSPECTION
1. BATTERY
2. TRANSMISSION GROUND
3. ATF LEVEL
4. FRONT DIFFERENTIAL OIL LEVEL
5. OPERATION OF SHIFT SELECT LEVER
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
4. Electrical Component Location
A: LOCATION
1. CONTROL MODULE
2. SENSOR
3. SOLENOID
4. OIL PRESSURE SWITCH
5. Transmission Control Module (TCM) I/O Signal
A: ELECTRICAL SPECIFICATION
6. Subaru Select Monitor
A: OPERATION
7. Read Current Data
A: OPERATION
8. Read Diagnostic Trouble Code (DTC)
A: OPERATION
9. Clear Memory Mode
A: OPERATION
10. Inspection Mode
A: PROCEDURE
11. Learning Control
A: GENERAL DESCRIPTION
B: PROCEDURE
1. PREPARATION FOR LEARNING
2. SIMPLE LEARNING
3. DRIVING CHECK
12. AT OIL TEMP Warning Light Display
A: OPERATION
B: INSPECTION
13. AWD Warning Light Display
A: OPERATION
B: INSPECTION
14. Diagnostic Procedure for Subaru Select Monitor Communication
A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
15. List of Diagnostic Trouble Code (DTC)
A: LIST
16. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
B: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW INPUT
C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH INPUT
D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT
E: DTC P0719 BRAKE SWITCH CIRCUIT LOW
F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT
G: DTC P0724 BRAKE SWITCH CIRCUIT HIGH
H: DTC P0731 GEAR 1 INCORRECT RATIO
I: DTC P0732 GEAR 2 INCORRECT RATIO
J: DTC P0733 GEAR 3 INCORRECT RATIO
K: DTC P0734 GEAR 4 INCORRECT RATIO
L: DTC P0735 GEAR 5 INCORRECT RATIO
M: DTC P0736 REVERSE INCORRECT RATIO
N: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR STUCK OFF
O: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL
P: DTC P0748 PRESSURE CONTROL SOLENOID “A” ELECTRICAL
Q: DTC P0751 SHIFT SOLENOID “A” PERFORMANCE OR STUCK OFF
R: DTC P0753 SHIFT SOLENOID “A” ELECTRICAL
S: DTC P0756 SHIFT SOLENOID “B” PERFORMANCE OR STUCK OFF
T: DTC P0758 SHIFT SOLENOID “B” ELECTRICAL
U: DTC P0761 SHIFT SOLENOID “C” PERFORMANCE OR STUCK OFF
V: DTC P0763 SHIFT SOLENOID “C” ELECTRICAL
W: DTC P0766 SHIFT SOLENOID “D” PERFORMANCE OR STUCK OFF
X: DTC P0768 SHIFT SOLENOID “D” ELECTRICAL
Y: DTC P0771 SHIFT SOLENOID “E” PERFORMANCE OR STUCK OFF
Z: DTC P0773 SHIFT SOLENOID “E” ELECTRICAL
AA: DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT
AB: DTC P0817 STARTER DISABLE CIRCUIT
AC: DTC P0957 BACKUP LIGHT RELAY CIRCUIT LOW
AD: DTC P0958 BACKUP LIGHT RELAY CIRCUIT HIGH
AE: DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR WHEEL)
AF: DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION
AG: DTC P1710 TORQUE CONVERTER TURBINE 2 SPEED SIGNAL CIRCUIT MALFUNCTION
AH: DTC P1718 AT CAN COMMUNICATION CIRCUIT
AI: DTC P1724 AT EEPROM ERROR
AJ: DTC P1817 SPORTS MODE SWITCH CIRCUIT (MANUAL SWITCH)
AK: DTC P1840 TRANSMISSION FLUID PRESSURE SENSOR SWITCH A CIRCUIT
AL: DTC P1841 TRANSMISSION FLUID PRESSURE SENSOR SWITCH B CIRCUIT
AM: DTC P1842 TRANSMISSION FLUID PRESSURE SENSOR SWITCH C CIRCUIT
AN: DTC P1843 TRANSMISSION FLUID PRESSURE SENSOR SWITCH D CIRCUIT
AO: DTC P1844 TRANSMISSION FLUID PRESSURE SENSOR SWITCH E CIRCUIT
17. Diagnostic Procedure without Diagnostic Trouble Code (DTC)
A: CHECK SHIFT INDICATOR
18. Diagnostics with Phenomenon
A: INSPECTION
MANUAL TRANSMISSION AND DIFFERENTIAL 6MT
1. General Description
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
2. TRANSMISSION GEAR OIL
B: COMPONENT
1. TRANSMISSION CASE
2. DRIVE PINION ASSEMBLY
3. MAIN SHAFT FOR SINGLE-RANGE
4. SHIFTER FORK AND SHIFTER ROD
5. TRANSFER CASE AND EXTENSION
6. SHIFT LINK ASSEMBLY
7. FRONT DIFFERENTIAL
8. TRANSMISSION MOUNTING
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Transmission Gear Oil
A: INSPECTION
B: REPLACEMENT
3. Manual Transmission Assembly
A: REMOVAL
B: INSTALLATION
4. Transmission Mounting System
A: REMOVAL
1. CROSSMEMBER AND CUSHION RUBBER
B: INSTALLATION
1. CROSSMEMBER AND CUSHION RUBBER
C: INSPECTION
1. CROSSMEMBER AND CUSHION RUBBER
5. Oil Seal
A: INSPECTION
B: REPLACEMENT
6. Differential Side Retainer Oil Seal
A: INSPECTION
B: REPLACEMENT
7. Switches and Harness
A: REMOVAL
1. BACK-UP LIGHT SWITCH & NEUTRAL POSITION SWITCH
B: INSTALLATION
1. BACK-UP LIGHT SWITCH & NEUTRAL POSITION SWITCH
C: INSPECTION
1. BACK-UP LIGHT SWITCH
2. NEUTRAL POSITION SWITCH
8. Preparation for Overhaul
A: PROCEDURE
9. Transfer Case and Extension Case Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. TRANSFER CASE
2. EXTENSION CASE
D: ASSEMBLY
1. TRANSFER CASE
2. EXTENSION CASE
10. Transfer Drive Gear
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
11. Transfer Driven Gear
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
12. Center Differential
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
13. Shift Link Assembly
A: REMOVAL
B: INSTALLATION
14. Transmission Case
A: REMOVAL
B: INSTALLATION
C: INSPECTION
15. Main Shaft Assembly for Single-Range
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
16. Drive Pinion Shaft Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
1. THRUST BEARING PRELOAD
17. Front Differential Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSY
2. SIDE RETAINER
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSY
2. SIDE RETAINER
E: INSPECTION
1. BEVEL PINION GEAR BACKLASH
2. HYPOID GEAR BACKLASH
3. TOOTH CONTACT OF HYPOID GEAR
F: ADJUSTMENT
1. BEVEL PINION GEAR BACKLASH
2. HYPOID GEAR BACKLASH
3. TOOTH CONTACT OF HYPOID GEAR
18. Reverse Idler Gear
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: ADJUSTMENT
19. Shifter Fork and Rod
A: REMOVAL
B: INSTALLATION
C: INSPECTION
20. General Diagnostic Table
A: INSPECTION
1. MANUAL TRANSMISSION
2. DIFFERENTIAL
CLUTCH SYSTEM CL
1. General Description
A: SPECIFICATION
B: COMPONENT
1. CLUTCH ASSEMBLY
2. CLUTCH PIPE AND HOSE
3. MASTER CYLINDER
4. OPERATING CYLINDER
5. CLUTCH PEDAL
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Clutch Disc and Cover
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CLUTCH DISC
2. CLUTCH COVER
3. Flywheel
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Release Bearing and Lever
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. RELEASE BEARING
2. RELEASE LEVER
5. Operating Cylinder
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
6. Master Cylinder
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Clutch Pipe and Hose
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Clutch Fluid
A: INSPECTION
B: REPLACEMENT
9. Clutch Fluid Air Bleeding
A: PROCEDURE
10. Clutch Pedal
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. CLUTCH PEDAL
F: ADJUSTMENT
11. Clutch Switch
A: REMOVAL
B: INSTALLATION
1. CLUTCH SWITCH
2. CLUTCH START SWITCH
C: INSPECTION
D: ADJUSTMENT
12. General Diagnostic Table
A: INSPECTION
1. CLUTCH
2. CLUTCH PEDAL
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
CHASSIS SECTION
FRONT SUSPENSION FS
1. General Description
A: SPECIFICATION
B: COMPONENT
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Wheel Alignment
A: INSPECTION
1. WHEEL ARCH HEIGHT
2. CAMBER
. INSPECTION
. FRONT CAMBER ADJUSTMENT
3. CASTER
. INSPECTION
4. STEERING ANGLE
. INSPECTION
. ADJUSTMENT
5. FRONT WHEEL TOE-IN
. INSPECTION
. ADJUSTMENT
6. REAR WHEEL TOE-IN
. INSPECTION
. ADJUSTMENT
7. THRUST ANGLE
. INSPECTION
. ADJUSTMENT
3. Cradle
A: REMOVAL
B: INSTALLATION
4. Front Stabilizer
A: REMOVAL
B: INSTALLATION
5. Front Ball Joint
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Front Arm
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. FRONT BUSHING
2. REAR BUSHING
D: ASSEMBLY
1. FRONT BUSHING
2. REAR BUSHING
E: INSPECTION
7. Front Strut
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. STRUT
2. STRUT MOUNT
3. DUST COVER
4. COIL SPRING
5. HELPER
F: DISPOSAL
8. General Diagnostic Table
A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
2. POOR RIDE COMFORT
3. NOISE
REAR SUSPENSION RS
1. General Description
A: SPECIFICATION
B: COMPONENT
1. REAR SUSPENSION
2. SHOCK ABSORBER
C: CAUTION
1. EACH PROCEDURE
2. OIL
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Wheel Alignment
A: INSPECTION
3. Rear Stabilizer
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Rear Trailing Link
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. REAR TRAILING LINK BUSHING
2. REAR HOUSING BUSHING
D: ASSEMBLY
1. REAR TRAILING LINK BUSHING
2. REAR HOUSING BUSHING
E: INSPECTION
5. Upper Arm
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Rear Shock Absorber
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
F: DISPOSAL
7. Front Lateral Link
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
8. Rear Lateral Link
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
9. Rear Sub Frame
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. General Diagnostic Table
A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
2. POOR RIDE COMFORT
3. NOISE
WHEEL AND TIRE SYSTEM WT
1. General Description
A: SPECIFICATION
1. SERVICE DATA
B: COMPONENT
C: PREPARATION TOOL
1. GENERAL TOOL
2. Tire and Wheel
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. TIRE
2. TIRE ROTATION
3. WHEEL BALANCING
3. “T-type” Tire
A: NOTE
B: REPLACEMENT
C: INSPECTION
4. Tire Pressure Monitoring System
A: REMOVAL
1. TRANSMITTER (TIRE INFLATION PRESSURE SENSOR)
2. TIRE PRESSURE MONITORING CONTROL MODULE
B: INSTALLATION
1. TRANSMITTER (TIRE INFLATION PRESSURE SENSOR)
2. TIRE PRESSURE MONITORING CONTROL MODULE
C: ADJUSTMENT
5. General Diagnostic Table
A: INSPECTION
TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS) TPM(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG”
2. TIRE PRESSURE MONITORING CONTROL MODULE
B: INSPECTION
1. TIRE
2. BATTERY
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
3. Electrical Component Location
A: LOCATION
4. Control Module I/O Signal
A: ELECTRICAL SPECIFICATION
B: WIRING DIAGRAM
5. Subaru Select Monitor
A: OPERATION
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
6. Read Diagnostic Trouble Code (DTC)
A: OPERATION
7. Clear Memory Mode
A: OPERATION
8. Read Current Data
A: OPERATION
B: LIST
9. Register Transmitter (ID)
A: OPERATION
10. Display Transmitter (ID)
A: OPERATION
11. Inspection Mode
A: PROCEDURE
12. Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern
A: INSPECTION
B: TIRE PRESSURE WARNING LIGHT DOES NOT COME ON
C: TIRE PRESSURE WARNING LIGHT DOES NOT COME OFF
D: TIRE PRESSURE WARNING LIGHT IS 25 TIMES BLINKING AND TURN ON
13. List of Diagnostic Trouble Code (DTC)
A: LIST
14. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC 11 TIRE 1 AIR PRESSURE DECREASE
B: DTC 12 TIRE 2 AIR PRESSURE DECREASE
C: DTC 13 TIRE 3 AIR PRESSURE DECREASE
D: DTC 14 TIRE 4 AIR PRESSURE DECREASE
E: DTC 21 TRANSMITTER 1 NO DATA
F: DTC 22 TRANSMITTER 2 NO DATA
G: DTC 23 TRANSMITTER 3 NO DATA
H: DTC 24 TRANSMITTER 4 NO DATA
I: DTC 31 TRANSMITTER 1 PRESSURE DATA ABNORMAL
J: DTC 32 TRANSMITTER 2 PRESSURE DATA ABNORMAL
K: DTC 33 TRANSMITTER 3 PRESSURE DATA ABNORMAL
L: DTC 34 TRANSMITTER 4 PRESSURE DATA ABNORMAL
M: DTC 41 TRANSMITTER 1 FUNCTION CODE ABNORMAL
N: DTC 42 TRANSMITTER 2 FUNCTION CODE ABNORMAL
O: DTC 43 TRANSMITTER 3 FUNCTION CODE ABNORMAL
P: DTC 44 TRANSMITTER 4 FUNCTION CODE ABNORMAL
Q: DTC 51 TRANSMITTER 1 BATTERY VOLTAGE DECREASE
R: DTC 52 TRANSMITTER 2 BATTERY VOLTAGE DECREASE
S: DTC 53 TRANSMITTER 3 BATTERY VOLTAGE DECREASE
T: DTC 54 TRANSMITTER 4 BATTERY VOLTAGE DECREASE
U: DTC 61 VEHICLE SPEED IS ABNORMAL
15. General Diagnostic Table
A: INSPECTION
DIFFERENTIALS DI
1. General Description
A: SPECIFICATION
1. REAR DIFFERENTIAL
2. IDENTIFICATION
3. REAR DIFFERENTIAL GEAR OIL
4. SERVICE DATA
B: COMPONENT
1. REAR DIFFERENTIAL (T-TYPE)
2. REAR DIFFERENTIAL (VA1-TYPE)
3. REAR DIFFERENTIAL (VA2-TYPE)
4. REAR DIFFERENTIAL MOUNTING SYSTEM
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Differential Gear Oil
A: INSPECTION
B: REPLACEMENT
3. Front Differential Assembly
A: NOTE
1. CVT MODEL
2. AT MODEL
3. MT MODEL
4. Rear Differential (T-type)
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. SIDE GEAR BACKLASH
2. HYPOID DRIVEN GEAR BACKLASH
3. HYPOID DRIVEN GEAR RUNOUT ON ITS BACK SURFACE
4. TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
5. TOTAL PRELOAD
6. COMPANION FLANGE
F: ADJUSTMENT
1. SIDE GEAR BACKLASH
2. HYPOID DRIVEN GEAR BACKLASH
3. TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
4. TOTAL PRELOAD
5. Rear Differential (VA-type)
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. VA1-TYPE
2. VA2-TYPE
D: ASSEMBLY
1. VA1-TYPE
2. VA2-TYPE
E: INSPECTION
1. SIDE GEAR BACKLASH
2. HYPOID DRIVEN GEAR BACKLASH
3. TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
4. COMPANION FLANGE
F: ADJUSTMENT
1. SIDE GEAR BACKLASH
2. HYPOID DRIVEN GEAR BACKLASH
3. TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
6. Rear Differential Front Oil Seal
A: INSPECTION
B: REPLACEMENT
7. Rear Differential Side Oil Seal
A: INSPECTION
B: REPLACEMENT
8. Rear Differential Front Member
A: REMOVAL
B: INSTALLATION
C: INSPECTION
9. Rear Differential Mount Bushing
A: INSPECTION
B: REPLACEMENT
10. Rear Differential Inspection Mode
A: GENERAL DESCRIPTION
B: PROCEDURE
11. General Diagnostic Table
A: INSPECTION
TRANSFER CASE TC
1. General Description
A: NOTE
2. Transfer Case and Extension Case Assembly
A: NOTE
3. Transfer Clutch
A: NOTE
4. Extension Case
A: NOTE
5. Oil Seal
A: NOTE
6. Transfer Drive Gear
A: NOTE
7. Transfer Driven Gear
A: NOTE
8. Center Differential Carrier
A: NOTE
9. Reduction Driven Gear
A: NOTE
10. Center Differential
A: NOTE
11. Transfer Clutch Pressure Test
A: NOTE
DRIVE SHAFT SYSTEM DS
1. General Description
A: SPECIFICATION
1. PROPELLER SHAFT
2. FRONT DRIVE SHAFT ASSEMBLY
3. REAR DRIVE SHAFT ASSEMBLY
B: COMPONENT
1. PROPELLER SHAFT
2. FRONT AXLE
3. REAR AXLE
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Propeller Shaft
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. JOINTS AND CONNECTIONS
2. SPLINES AND BEARING
3. RUNOUT OF PROPELLER SHAFT
4. CENTER BEARING FREE PLAY
3. Front Axle
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
4. Front Hub Unit Bearing
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
5. Rear Axle
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
6. Rear Hub Unit Bearing
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
7. Front Drive Shaft
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
8. Rear Drive Shaft
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
9. General Diagnostic Table
A: INSPECTION
VEHICLE DYNAMICS CONTROL (VDC) VDC
1. General Description
A: SPECIFICATION
B: COMPONENT
1. ABS WHEEL SPEED SENSOR
2. STEERING ANGLE SENSOR
3. VDC CONTROL MODULE & HYDRAULIC CONTROL UNIT (VDCCM&H/U)
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. VDC Control Module and Hydraulic Control Unit (VDCCM&H/U)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE
2. CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH THE BRAKE TESTER
3. CHECKING THE HYDRAULIC UNIT VDC OPERATION USING A PRESSURE GAUGE
4. CHECK HYDRAULIC UNIT VDC OPERATION WITH BRAKE TESTER
D: ADJUSTMENT
1. SET UP MODE FOR NEUTRAL OF STEERING ANGLE SENSOR & LATERAL G SENSOR 0 POINT
2. LONGITUDINAL G SENSOR & LATERAL G SENSOR 0 POINT SETTING MODE
3. ABS Sequence Control
A: OPERATION
1. ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR
2. CONDITIONS FOR ABS SEQUENCE CONTROL
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF ABS SEQUENCE CONTROL
4. VDC Sequence Control
A: OPERATION
1. VDC SEQUENCE CONTROL WITH SUBARU SELECT MONITOR
2. CONDITIONS FOR VDC SEQUENCE CONTROL
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF VDC SEQUENCE CONTROL
5. Yaw Rate and G Sensor
A: NOTE
B: INSPECTION
1. YAW RATE & LONGITUDINAL G AND LATERAL G SENSOR SIGNAL
6. Steering Angle Sensor
A: REPLACEMENT
7. Front ABS Wheel Speed Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CHECK WITH SUBARU SELECT MONITOR
2. ABS WHEEL SPEED SENSOR
8. Rear ABS Wheel Speed Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. ABS WHEEL SPEED SENSOR
9. Front Magnetic Encoder
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Rear Magnetic Encoder
A: REMOVAL
B: INSTALLATION
C: INSPECTION
11. VDC OFF Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS) VDC(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. Check List for Interview
A: CHECK
1. STATE OF ABS WARNING LIGHT
2. STATE OF VDC WARNING LIGHT & VDC INDICATOR LIGHT
3. STATE OF VDC OFF INDICATOR LIGHT
4. CONDITIONS UNDER WHICH TROUBLE OCCURS
3. General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG”
B: INSPECTION
1. BATTERY
2. GROUND
3. BRAKE FLUID
4. HYDRAULIC UNIT
5. BRAKE DRAG
6. BRAKE PAD AND ROTOR
7. TIRE
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
4. Electrical Component Location
A: LOCATION
5. Control Module I/O Signal
A: ELECTRICAL SPECIFICATION
B: WIRING DIAGRAM
6. Subaru Select Monitor
A: OPERATION
1. HOW TO USE SUBARU SELECT MONITOR
2. READ CURRENT DATA
3. FUNCTION CHECK
4. FREEZE FRAME DATA
5. PARAMETER SELECTION
6. PARAMETER CHECK
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
7. Read Diagnostic Trouble Code (DTC)
A: OPERATION
8. Inspection Mode
A: PROCEDURE
9. Clear Memory Mode
A: OPERATION
10. Warning Light Illumination Pattern
A: INSPECTION
B: ABS WARNING LIGHT, VDC OFF INDICATOR LIGHT, VDC WARNING LIGHT AND VDC INDICATOR LIGHT DO NOT COME ON
C: ABS WARNING LIGHT DOES NOT GO OFF
D: VDC WARNING LIGHT AND VDC INDICATOR LIGHT DO NOT GO OFF
E: VDC OFF INDICATOR LIGHT DOES NOT GO OFF
F: BRAKE WARNING LIGHT DOES NOT GO OFF
11. List of Diagnostic Trouble Code (DTC)
A: LIST
12. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC C0021 FRONT RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT
B: DTC C0023 FRONT LEFT ABS SENSOR CIRCUIT OPEN OR SHORT
C: DTC C0025 REAR RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT
D: DTC C0027 REAR LEFT ABS SENSOR CIRCUIT OPEN OR SHORT
E: DTC C0022 FRONT RIGHT ABS SENSOR SIGNAL
F: DTC C0024 FRONT LEFT ABS SENSOR SIGNAL
G: DTC C0026 REAR RIGHT ABS SENSOR SIGNAL
H: DTC C0028 REAR LEFT ABS SENSOR SIGNAL
I: DTC C0031 FR HOLD VALVE MALFUNCTION
J: DTC C0032 FR PRESSURE REDUCING VALVE MALFUNCTION
K: DTC C0033 FL HOLD VALVE MALFUNCTION
L: DTC C0034 FL PRESSURE REDUCING VALVE MALFUNCTION
M: DTC C0035 RR HOLD VALVE MALFUNCTION
N: DTC C0036 RR PRESSURE REDUCING VALVE MALFUNCTION
O: DTC C0037 RL HOLD VALVE MALFUNCTION
P: DTC C0038 RL PRESSURE REDUCING VALVE MALFUNCTION
Q: DTC C0061 NORMAL OPENING VALVE 1 MALFUNCTION
R: DTC C0062 NORMAL OPENING VALVE 2 MALFUNCTION
S: DTC C0063 NORMAL CLOSING VALVE 1 MALFUNCTION
T: DTC C0064 NORMAL CLOSING VALVE 2 MALFUNCTION
U: DTC C0041 ECM
V: DTC C0041 PARAMETER SELECTION ERROR
W: DTC C0042 POWER SUPPLY VOLTAGE FAILURE
X: DTC C0044 TCM COMMUNICATION CIRCUIT
Y: DTC C0045 TCM MALFUNCTION
Z: DTC C0045 INCORRECT VDC CONTROL MODULE SPECIFICATIONS
AA: DTC C0046 BODY INTEGRATED MODULE COMMUNICATION CIRCUIT
AB: DTC C0047 CAN COMMUNICATION
AC: DTC C0048 PARKING BRAKE SYSTEM COMMUNICATION CIRCUIT
AD: DTC C0051 VALVE RELAY
AE: DTC C0052 MOTOR MALFUNCTION
AF: DTC C0054 BLS OFF MALFUNCTION
AG: DTC C0054 BLS ON MALFUNCTION
AH: DTC C0056 G SENSOR FAILURE
AI: DTC C0056 G SENSOR SIGNAL
AJ: DTC C0057 ECM COMMUNICATION CIRCUIT
AK: DTC C0057 ECM CONTROL SYSTEM
AL: DTC C0057 VDC INTERUPTED DUE TO EGI REASON
AM: DTC C0071 NO SIGNAL FROM STEERING ANGLE SENSOR
AN: DTC C0071 STEER ANGLE SENSOR OP
AO: DTC C0072 ABNORMAL YAW RATE SENSOR OUTPUT
AP: DTC C0073 LATERAL G SENSOR POWER/OUTPUT
AQ: DTC C0073 ABNORMAL LATERAL G SENSOR OUTPUT
AR: DTC C0074 MASTER CYLINDER PRESSURE SENSOR OUTPUT
AS: DTC C0075 WHEEL CYLINDER PRESSURE SENSOR OUTPUT
AT: DTC C0081 SYSTEM FAILURE
13. General Diagnostic Table
A: INSPECTION
BRAKE BR
1. General Description
A: SPECIFICATION
B: COMPONENT
1. FRONT DISC BRAKE
2. REAR DISC BRAKE
3. MASTER CYLINDER
4. FRONT BRAKE PIPES AND HOSES
5. CENTER AND REAR BRAKE PIPES AND HOSES
6. BRAKE BOOSTER
7. BRAKE PEDAL
C: CAUTION
2. Front Brake Pad
A: REMOVAL
B: INSTALLATION
1. 16-INCH TYPE
2. 17-INCH TYPE
C: INSPECTION
1. 16-INCH TYPE
2. 17-INCH TYPE
3. Front Disc Rotor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Front Disc Brake Assembly
A: REMOVAL
B: INSTALLATION
1. 16-INCH TYPE
2. 17-INCH TYPE
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
5. Rear Brake Pad
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Rear Disc Rotor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Rear Disc Brake Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
8. Master Cylinder
A: REMOVAL
B: INSTALLATION
C: REPLACEMENT
9. Brake Booster
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. OPERATION CHECK (WITHOUT GAUGES)
. Check without gauges
. AIR TIGHTNESS CHECK
. CHECK OPERATION.
. LOADED AIR TIGHTNESS CHECK
2. OPERATION CHECK (WITH GAUGES)
. CHECK WITH GAUGE
. AIR TIGHTNESS CHECK
. LOADED AIR TIGHTNESS CHECK
. LACK OF BOOST ACTION CHECK
. BOOSTING ACTION CHECK
10. Brake Fluid
A: INSPECTION
B: REPLACEMENT
11. Air Bleeding
A: PROCEDURE
1. MASTER CYLINDER
2. BRAKE LINE
12. Brake Hose
A: REMOVAL
1. FRONT BRAKE HOSE
2. REAR BRAKE HOSE
B: INSTALLATION
1. FRONT BRAKE HOSE
2. REAR BRAKE HOSE
C: INSPECTION
13. Brake Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
14. Brake Pedal
A: REMOVAL
1. AT MODEL
2. MT MODEL
B: INSTALLATION
1. AT MODEL
2. MT MODEL
C: INSPECTION
15. Stop Light Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CHECK SPECIFIED POSITION
2. CHECK RESISTANCE
D: ADJUSTMENT
16. General Diagnostic Table
A: INSPECTION
PARKING BRAKE PB
1. General Description
A: SPECIFICATION
B: COMPONENT
1. PARKING BRAKE (REAR DISC BRAKE)
2. PARKING BRAKE ACTUATOR
C: CAUTION
D: PREPARATION TOOL
1. ST
2. GENERAL TOOL
2. Parking Brake Actuator
A: REMOVAL
B: INSTALLATION
3. Parking Brake Assembly (Rear Disc Brake)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
D: ADJUSTMENT
1. SHOE CLEARANCE
4. Parking Brake Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. PARKING BRAKE CONTROL SWITCH
2. HILL HOLD SWITCH
5. Emergency Release of Electronic Parking Brake
A: OPERATION
B: INSPECTION
6. General Diagnostic Table
A: INSPECTION
PARKING BRAKE (DIAGNOSTICS) PB(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. Check List for Interview
A: CHECK
1. STATE OF BRAKE WARNING LIGHT
2. STATE OF ELECTRONIC PARKING BRAKE WARNING LIGHT (C6 MODEL ONLY)
3. HILL HOLD INDICATOR LIGHT CONDITION
4. CONDITIONS UNDER WHICH TROUBLE OCCURS
3. General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG”
B: INSPECTION
1. BATTERY
2. GROUND
3. BRAKE DRAG
4. PARKING BRAKE ASSEMBLY
5. TIRE
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
4. Electrical Component Location
A: LOCATION
5. Control Module I/O Signal
A: ELECTRICAL SPECIFICATION
B: WIRING DIAGRAM
6. Subaru Select Monitor
A: OPERATION
1. HOW TO USE SUBARU SELECT MONITOR
2. READ CURRENT DATA
3. MAINTENANCE OPERATION MODE
4. FREEZE FRAME DATA
5. PARKING BRAKE REMOVAL MODE
6. FORCE SENSOR CALIBRATION MODE
7. BREAK-IN PARKING BRAKE DRIVE MODE
8. PARAMETER INITIALIZATION MODE
9. CLUTCH SENSOR CALIBRATION MODE
10. CLUTCH ENGAGEMENT POSITION SETTING
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
7. Read Diagnostic Trouble Code (DTC)
A: OPERATION
8. Inspection Mode
A: PROCEDURE
9. Clear Memory Mode
A: OPERATION
10. Warning Light Illumination Pattern
A: INSPECTION
B: BRAKE WARNING LIGHT, ELECTRONIC PARKING BRAKE WARNING LIGHT AND HILL HOLD INDICATOR LIGHT DO NOT COME ON
C: HILL HOLD INDICATOR LIGHT DO NOT GO OFF
D: ELECTRONIC PARKING BRAKE WARNING LIGHT AND HILL HOLD INDICATOR LIGHT DO NOT GO OFF
E: BRAKE WARNING LIGHT DOES NOT GO OFF
F: BRAKE WARNING LIGHT REMAINS BLINKING
11. List of Diagnostic Trouble Code (DTC)
A: LIST
12. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC C0221 PARKING POSITION SWITCH
B: DTC C0222 HILL HOLD SWITCH CIRCUIT
C: DTC C0231 ECM FAILURE
D: DTC C0232 AT ABNORMAL
E: DTC C0233 MT SHIFT SWITCH CIRCUIT
F: DTC C0234 VDC FAILURE
G: DTC C0235 IGNITION SWITCH CIRCUIT
H: DTC C0241 ELECTRICAL CONTROL MODULE
I: DTC C0242 POWER SUPPLY VOLTAGE FAILURE
J: DTC C0242 INTERNAL POWER SUPPLY VOLTAGE ABNORMAL
K: DTC C0243 PARAMETER SELECTION ERROR
L: DTC C0251 ACTUATOR LINE (ABNORMAL)
M: DTC C0252 MOTOR MALFUNCTION
N: DTC C0253 ACTUATOR STROKE EXCESS
O: DTC C0261 IMPROPER CAN COMMUNICATION
P: DTC C0262 TCM COMMUNICATION CIRCUIT
Q: DTC C0263 ECM COMMUNICATION CIRCUIT
R: DTC C0264 VDC COMMUNICATION SYSTEM
S: DTC C0265 BODY INTEGRATED MODULE COMMUNICATION CIRCUIT
T: DTC C0267 METER COMMUNICATION SYSTEM
U: DTC C0271 FORCE SENSOR LINE (ABNORMAL)
V: DTC C0272 TEMPERATURE SENSOR LINE (ABNORMAL)
W: DTC C0273 STROKE SENSOR LINE (ABNORMAL)
X: DTC C0274 CLUTCH SENSOR CIRCUIT
Y: DTC C0275 LONGITUDINAL G SENSOR CIRCUIT
Z: DTC C0281 MID STOP CONDITION
AA: DTC C0282 EMERGENCY CANCEL STATUS
13. General Diagnostic Table
A: INSPECTION
POWER ASSISTED SYSTEM (POWER STEERING) PS
1. General Description
A: SPECIFICATION
B: COMPONENT
1. STEERING WHEEL AND COLUMN
2. HOSE AND TANK
3. STEERING GEARBOX
4. OIL PUMP
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Steering Wheel
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
3. Universal Joint
A: REMOVAL
B: INSTALLATION
C: INSPECTION
4. Steering Column
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. BASIC INSPECTION
2. INSPECTION OF AIRBAG SYSTEM
5. Steering Gearbox
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
E: INSPECTION
1. BASIC INSPECTION
2. SERVICE LIMIT
3. RACK SHAFT PLAY IN THE RADIAL DIRECTION
4. INPUT SHAFT PLAY
5. TURNING RESISTANCE OF GEARBOX
6. OIL LEAKAGE
F: ADJUSTMENT
1. GEARBOX BACKLASH ADJUSTMENT (SERVICING ON VEHICLE)
2. FRONT WHEEL ALIGNMENT ADJUSTMENT
6. Pipe Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Oil Pump
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. BASIC INSPECTION
2. SERVICE LIMIT
3. HYDRAULIC PRESSURE
8. Reservoir Tank
A: REMOVAL
B: INSTALLATION
C: INSPECTION
9. Power Steering Fluid
A: SPECIFICATION
B: INSPECTION
C: REPLACEMENT
10. General Diagnostic Table
A: INSPECTION
1. NOISE AND VIBRATION
2. MEASUREMENT OF STEERING EFFORT
BODY SECTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C) AC
1. General Description
A: SPECIFICATION
1. HEATER SYSTEM
2. A/C SYSTEM
B: COMPONENT
1. HEATER COOLING UNIT
2. BLOWER MOTOR UNIT
3. CONTROL MODULE
4. AIR CONDITIONING UNIT
5. COMPRESSOR
6. HEATER DUCT
C: CAUTION
1. HFC-134A A/C SYSTEM
2. COMPRESSOR OIL
3. REFRIGERANT
4. HANDLING OF REFRIGERANT
5. O-RING CONNECTIONS
D: PREPARATION TOOL
2. Refrigerant Pressure with Manifold Gauge Set
A: PROCEDURE
B: INSPECTION
3. Refrigerant Recovery Procedure
A: PROCEDURE
4. Refrigerant Charging Procedure
A: PROCEDURE
5. Refrigerant Leak Check
A: INSPECTION
6. Relay and Fuse
A: LOCATION
B: INSPECTION
1. CHECK FUSE.
2. CHECK RELAY
7. Compressor Oil
A: PROCEDURE
B: REPLACEMENT
8. Blower Motor Unit Assembly
A: REMOVAL
B: INSTALLATION
9. Blower Motor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Power Transistor (Auto A/C Model)
A: REMOVAL
B: INSTALLATION
11. Blower Resistor (Manual A/C Model)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
12. Heater Core
A: REMOVAL
B: INSTALLATION
13. Control Panel
A: REMOVAL
1. AUTO A/C MODEL
2. MANUAL A/C MODEL
B: INSTALLATION
14. Control Unit
A: REMOVAL
B: INSTALLATION
15. Compressor
A: REMOVAL
B: INSTALLATION
16. Condenser
A: REMOVAL
B: INSTALLATION
C: INSPECTION
17. Heater and Cooling Unit
A: REMOVAL
B: INSTALLATION
18. Evaporator
A: REMOVAL
B: INSTALLATION
C: INSPECTION
19. Hose and Pipe
A: REMOVAL
B: INSTALLATION
C: INSPECTION
20. Pressure Sensor
A: INSPECTION
21. Ambient Sensor (Auto A/C Model)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
22. Sunload Sensor (Auto A/C Model)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
23. In-Vehicle Sensor (Auto A/C Model)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
24. Air Vent Grille
A: REMOVAL
1. CENTER GRILLE ASSEMBLY
2. SIDE GRILLE ASSEMBLY RH
3. SIDE GRILLE ASSEMBLY LH
B: INSTALLATION
C: INSPECTION
25. Heater Duct
A: REMOVAL
B: INSTALLATION
26. Heater Vent Duct
A: REMOVAL
B: INSTALLATION
27. A/C Filter
A: REPLACEMENT
28. General Diagnostic Table
A: INSPECTION
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) AC(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. General Description
A: CAUTION
B: INSPECTION
1. BATTERY
2. ASPIRATOR HOSE
3. A/C LINE
4. CONTROL LINKAGE
5. CONTROL SWITCHES
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
3. Electrical Component Location
A: LOCATION
1. ENGINE COMPARTMENT
2. PASSENGER COMPARTMENT
4. Auto A/C Control Module I/O Signal
A: ELECTRICAL SPECIFICATION
B: WIRING DIAGRAM
1. AIR CONDITIONER A/C MODEL
5. Diagnostic Chart for Self-Diagnosis
A: OPERATION
1. A/C CONTROL SYSTEM SELF-DIAGNOSIS
2. SENSOR CHECK TABLE
3. OPERATING MODE TABLE
6. Diagnostics for A/C System Malfunction
A: A/C OR SELF-DIAGNOSIS SYSTEMS DO NOT OPERATE
B: BLOWER MOTOR DOES NOT ROTATE
C: COMPARTMENT TEMPERATURE DOES NOT CHANGE, OR A/C SYSTEM DOES NOT RESPOND PROMPTLY
7. Diagnostic Procedure for Sensors
A: AMBIENT SENSOR
8. Subaru Select Monitor
A: OPERATION
9. Read Diagnostic Trouble Code (DTC)
A: OPERATION
10. Clear Memory Mode
A: OPERATION
11. Read Current Data
A: OPERATION
B: LIST
12. Diagnostic Procedure for Subaru Select Monitor Communication
A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
13. List of Diagnostic Trouble Code (DTC)
A: LIST
14. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC B1601 IN-VEHICLE SENSOR SHORT
B: DTC B1602 IN-VEHICLE SENSOR OPEN
C: DTC B1603 EVAPORATOR SENSOR SHORT
D: DTC B1604 EVAPORATOR SENSOR OPEN
E: DTC B1605 REFRIGERANT PRESSURE SENSOR CIRCUIT OPEN
F: DTC B1606 REFRIGERANT PRESSURE SENSOR CIRCUIT SHORT
G: DTC B1607 SUNLOAD SENSOR SHORT
H: DTC B1608 SUNLOAD SENSOR OPEN
I: DTC B1610 AIRMIX DOOR ACTUATOR POTENTIOMETER CIRCUIT OPEN (DRIVER’S)
J: DTC B1611 AIRMIX DOOR ACTUATOR POTENTIOMETER CIRCUIT SHORT (DRIVER’S)
K: DTC B1612 AIRMIX DOOR ACTUATOR LOCK (DRIVER’S)
L: DTC B1613 AIRMIX DOOR ACTUATOR POTENTIOMETER CIRCUIT OPEN (PASSENGER’S)
M: DTC B1614 AIRMIX DOOR ACTUATOR POTENTIOMETER CIRCUIT SHORT (PASSENGER’S)
N: DTC B1615 AIRMIX DOOR ACTUATOR LOCK (PASSENGER’S)
O: DTC B1620 MODE DOOR ACTUATOR POTENTIOMETER CIRCUIT OPEN
P: DTC B1621 MODE DOOR ACTUATOR POTENTIOMETER CIRCUIT SHORT
Q: DTC B1622 MODE DOOR ACTUATOR LOCK
R: DTC U0028 HEATER CONTROL PANEL COMMUNICATION ERROR
S: DTC U0001 CAN COMMUNICATION BUS OFF
T: DTC U0002 CAN COMMUNICATION ERROR
U: DTC B1641 REFRIGERANT FLOW SENSOR CIRCUIT SHORT
V: DTC B1642 REFRIGERANT FLOW SENSOR CIRCUIT OPEN
W: DTC B1643 VARIABLE FLOW CHANGE SOLENOID DUTY CIRCUIT ABNORMAL
X: DTC B1644 REFRIGERANT NOT SEALED DRIVE ERROR
15. Diagnostics with Phenomenon
A: INSPECTION
AIRBAG SYSTEM AB
1. General Description
A: COMPONENT
1. DRIVER’S AIRBAG MODULE
2. PASSENGER’S AIRBAG MODULE
3. SIDE AIRBAG MODULE
4. CURTAIN AIRBAG MODULE
5. AIRBAG CONTROL MODULE
6. FRONT SUB SENSOR
7. SIDE AIRBAG SENSOR
8. CURTAIN AIRBAG SENSOR
9. STEERING ROLL CONNECTOR
B: CAUTION
1. BEFORE STARTING ALL WORKS
2. BEFORE STARTING PARTS REPLACEMENT
3. BEFORE STARTING TROUBLESHOOTING
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Airbag Connector
A: PROCEDURE
1. POWER SUPPLY
2. AIRBAG CONTROL MODULE
3. DRIVER’S AIRBAG MODULE (ROLL CONNECTOR)
4. PASSENGER’S AIRBAG MODULE
5. DRIVER’S AIRBAG MODULE, CURTAIN AIRBAG MODULE & PRETENSIONER
6. FRONT SUB SENSOR, SIDE AIRBAG SENSOR, CURTAIN AIRBAG SENSOR
7. SIDE AIRBAG MODULE
8. BUCKLE SWITCH RH
9. OCCUPANT DETECTION SYSTEM (BETWEEN AIRBAG REAR HARNESS AND SEAT HARNESS)
3. Inspection Locations After a Collision
A: INSPECTION
1. DRIVER’S AIRBAG MODULE
2. PASSENGER’S AIRBAG MODULE
3. SIDE AIRBAG MODULE
4. CURTAIN AIRBAG MODULE
5. AIRBAG CONTROL MODULE
6. FRONT SUB SENSOR
7. SIDE AIRBAG SENSOR AND CURTAIN AIRBAG SENSOR
8. ROLL CONNECTOR
9. STEERING SHAFT
10. PASSENGER’S SEAT
11. INSPECTION OF OTHER PARTS
4. Driver’s Airbag Module
A: REMOVAL
B: INSTALLATION
5. Passenger’s Airbag Module
A: REMOVAL
B: INSTALLATION
6. Side Airbag Module
A: REMOVAL
B: INSTALLATION
7. Curtain Airbag Module
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
8. Airbag Control Module
A: REMOVAL
B: INSTALLATION
9. Front Sub Sensor
A: REMOVAL
B: INSTALLATION
10. Side Airbag Sensor
A: REMOVAL
B: INSTALLATION
11. Curtain Airbag Sensor
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
12. Roll Connector
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. VISUAL INSPECTION
2. UNIT INSPECTION OF ROLL CONNECTOR
D: ADJUSTMENT
AIRBAG SYSTEM (DIAGNOSTICS) AB(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. Check List for Interview
A: CHECK
3. General Description
A: CAUTION
B: INSPECTION
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
4. Electrical Component Location
A: LOCATION
5. Airbag Connector
A: PROCEDURE
6. Airbag Control Module I/O Signal
A: ELECTRICAL SPECIFICATION
B: WIRING DIAGRAM
7. Subaru Select Monitor
A: OPERATION
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
8. Read Diagnostic Trouble Code (DTC)
A: OPERATION
9. Inspection Mode
A: PROCEDURE
10. Clear Memory Mode
A: OPERATION
11. Display of Status Information
A: OPERATION
12. Airbag Warning Light Illumination Pattern
A: INSPECTION
13. Airbag Warning Light Failure
A: AIRBAG WARNING LIGHT REMAINS ON
B: AIRBAG WARNING LIGHT REMAINS OFF
14. List of Diagnostic Trouble Code (DTC)
A: LIST
15. Diagnostic Chart with Trouble Code
A: DTC 11 DRIVER’S AIRBAG FAILURE
B: DTC 12 PASSENGER’S AIRBAG FAILURE
C: DTC 15 DRIVER’S AIRBAG FAILURE
D: DTC 16 PASSENGER’S AIRBAG FAILURE
E: DTC 1A DRIVER’S AIRBAG FAILURE
F: DTC 1B PASSENGER’S AIRBAG FAILURE
G: DTC 1D DRIVER’S AIRBAG FAILURE
H: DTC 1E PASSENGER’S AIRBAG FAILURE
I: DTC 21 AIRBAG ECM FAILURE
J: DTC 22 FRONT AIRBAG FIRING OUTPUT
K: DTC 26 PASSENGER’S AIRBAG INDICATOR FAILURE
L: DTC 27 ODS COMMUNICATION ERROR
M: DTC 29 ODS FAILURE
N: DTC 2A ODS CALIBRATION ERROR
O: DTC 2B ODS SYSTEM WRONG PARTS
P: DTC 2D AIRBAG WARNING INDICATOR FAILURE
Q: DTC 33 FRONT SUB SENSOR RH FAILURE
R: DTC 34 FRONT SUB SENSOR LH FAILURE
S: DTC 37 BUCKLE SWITCH RH FAILURE
T: DTC 39 SEAT BELT WARNING FAILURE
U: DTC 3A FRONT SUB SENSOR RH FALSE INSTALLATION
V: DTC 3B FRONT SUB SENSOR LH FALSE INSTALLATION
W: DTC 41 SIDE AIRBAG RH FAILURE
X: DTC 42 SIDE AIRBAG LH FAILURE
Y: DTC 45 SIDE AIRBAG RH FAILURE
Z: DTC 46 SIDE AIRBAG LH FAILURE
AA: DTC 4A SIDE AIRBAG RH FAILURE
AB: DTC 4B SIDE AIRBAG LH FAILURE
AC: DTC 4D SIDE AIRBAG RH FAILURE
AD: DTC 4E SIDE AIRBAG LH FAILURE
AE: DTC 53 SIDE AIRBAG SENSOR RH FAILURE
AF: DTC 54 SIDE AIRBAG SENSOR LH FAILURE
AG: DTC 55 SIDE CURTAIN AIRBAG FIRING OUTPUT
AH: DTC 58 CURTAIN AIRBAG SENSOR RH FAILURE
AI: DTC 59 CURTAIN AIRBAG SENSOR LH FAILURE
AJ: DTC 5A SIDE AIRBAG SENSOR RH FALSE INSTALLATION
AK: DTC 5B SIDE AIRBAG SENSOR LH FALSE INSTALLATION
AL: DTC 5C CURTAIN AIRBAG SENSOR RH FALSE INSTALLATION
AM: DTC 5D CURTAIN AIRBAG SENSOR LH FALSE INSTALLATION
AN: DTC 61 BELT PRETENSIONER RH FAILURE
AO: DTC 62 BELT PRETENSIONER LH FAILURE
AP: DTC 65 BELT PRETENSIONER RH FAILURE
AQ: DTC 66 BELT PRETENSIONER LH FAILURE
AR: DTC 6A BELT PRETENSIONER RH FAILURE
AS: DTC 6B BELT PRETENSIONER LH FAILURE
AT: DTC 6D BELT PRETENSIONER RH FAILURE
AU: DTC 6E BELT PRETENSIONER LH FAILURE
AV: DTC 71 DRIVER’S AIRBAG FAILURE
AW: DTC 72 PASSENGER’S AIRBAG FAILURE
AX: DTC 75 DRIVER’S AIRBAG FAILURE
AY: DTC 76 PASSENGER’S AIRBAG FAILURE
AZ: DTC 7A DRIVER’S AIRBAG FAILURE
BA: DTC 7B PASSENGER’S AIRBAG FAILURE
BB: DTC 7D DRIVER’S AIRBAG FAILURE
BC: DTC 7E PASSENGER’S AIRBAG FAILURE
BD: DTC 91 CURTAIN AIRBAG MODULE RH FAILURE
BE: DTC 92 CURTAIN AIRBAG MODULE LH FAILURE
BF: DTC 95 CURTAIN AIRBAG MODULE RH FAILURE
BG: DTC 96 CURTAIN AIRBAG MODULE LH FAILURE
BH: DTC 9A CURTAIN AIRBAG MODULE RH FAILURE
BI: DTC 9B CURTAIN AIRBAG MODULE LH FAILURE
BJ: DTC 9D CURTAIN AIRBAG MODULE RH FAILURE
BK: DTC 9E CURTAIN AIRBAG MODULE LH FAILURE
BL: DTC A1 FRONT SENSOR BUS COMMUNICATION ERROR
BM: DTC BB ROLL OVER:FIRING OUTPUT
BN: DTC E3 FRONT SENSOR BUS RH COMMUNICATION ERROR
BO: DTC E4 FRONT SENSOR BUS RH COMMUNICATION ERROR
BP: DTC E7 FRONT SENSOR BUS LH COMMUNICATION ERROR
BQ: DTC E8 FRONT SENSOR BUS LH COMMUNICATION ERROR
BR: DTC E9 SIDE SENSOR BUS RH COMMUNICATION ERROR
BS: DTC EB SIDE SENSOR BUS RH COMMUNICATION ERROR
BT: DTC EC SIDE SENSOR BUS RH COMMUNICATION ERROR
BU: DTC ED SIDE SENSOR BUS RH COMMUNICATION ERROR
BV: DTC EE SIDE SENSOR BUS RH COMMUNICATION ERROR
BW: DTC F1 SIDE SENSOR BUS LH COMMUNICATION ERROR
BX: DTC F3 SIDE SENSOR BUS LH COMMUNICATION ERROR
BY: DTC F4 SIDE SENSOR BUS LH COMMUNICATION ERROR
BZ: DTC F5 SIDE SENSOR BUS LH COMMUNICATION ERROR
CA: DTC F6 SIDE SENSOR BUS LH COMMUNICATION ERROR
OCCUPANT DETECTION SYSTEM (DIAGNOSTICS) OD(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. Check List for Interview
A: CHECK
3. General Description
A: CAUTION
B: INSPECTION
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
4. Electrical Component Location
A: LOCATION
5. Airbag Connector
A: PROCEDURE
1. OCCUPANT DETECTION SYSTEM (BETWEEN AIRBAG REAR HARNESS AND SEAT HARNESS)
2. AIRBAG CONTROL MODULE
3. BUCKLE SWITCH RH
6. Control Module I/O Signal
A: ELECTRICAL SPECIFICATION
B: WIRING DIAGRAM
7. Subaru Select Monitor
A: OPERATION
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
8. Read Diagnostic Trouble Code (DTC)
A: OPERATION
9. Inspection Mode
A: PROCEDURE
10. Clear Memory Mode
A: OPERATION
11. Display of Status Information
A: OPERATION
12. System Calibration (Rezeroing)
A: OPERATION
13. Airbag Warning Light Illumination Pattern
A: INSPECTION
14. Passenger’s Airbag ON/OFF Indicator Light Illumination Pattern
A: INSPECTION
15. List of Diagnostic Trouble Code (DTC)
A: LIST
16. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC 27 ODS COMMUNICATION ERROR
B: DTC 29 ODS FAILURE
C: DTC 2A ODS CALIBRATION ERROR
D: DTC 2B ODS SYSTEM WRONG PARTS
E: DTC 37 BUCKLE SWITCH RH FAILURE
SEAT BELT SYSTEM SB
1. General Description
A: COMPONENT
1. FRONT SEAT BELT
2. REAR SEAT BELT (SEDAN MODEL)
3. REAR SEAT BELT (OUTBACK MODEL)
B: CAUTION
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Pretensioner Connector
A: PROCEDURE
3. Inspection Locations After a Collision
A: INSPECTION
4. Seat Belt Warning System
A: WIRING DIAGRAM
B: INSPECTION
5. Front Seat Belt
A: REMOVAL
1. OUTER BELT ASSY
2. INNER BELT ASSY
3. ADJUSTABLE ANCHOR ASSY
B: INSTALLATION
1. OUTER BELT ASSY
2. INNER BELT ASSY
3. ADJUSTABLE ANCHOR ASSY
C: INSPECTION
1. VISUAL INSPECTION
2. ELR LOCK MECHANISM INSPECTION
3. SEAT BELT SWITCH INSPECTION
6. Rear Seat Belt
A: REMOVAL
1. OUTER BELT ASSEMBLY RH & LH (SEDAN MODEL)
2. OUTER BELT ASSEMBLY RH & LH (OUTBACK MODEL)
3. SHOULDER BELT ASSEMBLY CTR (SEDAN MODEL)
4. SHOULDER BELT ASSEMBLY CTR (OUTBACK MODEL)
5. CENTER BELT RH ASSEMBLY & LH ASSEMBLY
B: INSTALLATION
1. OUTER BELT RH ASSEMBLY & LH ASSEMBLY (SEDAN MODEL)
2. OUTER BELT RH ASSEMBLY & LH ASSEMBLY (OUTBACK MODEL)
3. SHOULDER BELT CTR ASSEMBLY (SEDAN MODEL)
4. SHOULDER BELT CTR ASSEMBLY (OUTBACK MODEL)
5. CENTER BELT ASSEMBLY RH & LH
C: INSPECTION
1. VISUAL INSPECTION
2. ELR LOCK MECHANISM INSPECTION
LIGHTING SYSTEM LI
1. General Description
A: SPECIFICATION
B: CAUTION
C: PREPARATION TOOL
1. GENERAL TOOL
2. Relay and Fuse
A: LOCATION
B: INSPECTION
1. CHECK FUSE.
2. CHECK RELAY
3. Headlight System
A: WIRING DIAGRAM
B: INSPECTION
1. AUTO HEADLIGHT SYSTEM CHECK
2. CHECK LIGHTING SWITCH
3. CHECK DIMMER & PASSING SWITCH
C: NOTE
4. Day Time Running Light System
A: WIRING DIAGRAM
B: INSPECTION
1. DAYTIME RUNNING LIGHT SYSTEM CHECK
C: NOTE
5. Clearance Light and Illumination Light System
A: WIRING DIAGRAM
B: INSPECTION
1. CHECK LIGHTING SWITCH
C: NOTE
6. Front Fog Light System
A: WIRING DIAGRAM
B: INSPECTION
1. CHECK FRONT FOG LIGHT SWITCH
C: NOTE
7. Turn Signal Light and Hazard Light System
A: WIRING DIAGRAM
B: INSPECTION
1. CHECK TURN SIGNAL SWITCH
2. CHECK HAZARD SWITCH
3. CHECK TURN SIGNAL AND HAZARD MODULE
C: NOTE
8. Back-up Light System
A: WIRING DIAGRAM
B: INSPECTION
1. CHECK BACK-UP LIGHT SWITCH (MT MODEL)
2. CHECK INHIBITOR SWITCH (CVT MODEL)
C: NOTE
9. Stop Light System
A: WIRING DIAGRAM
B: INSPECTION
1. CHECK STOP LIGHT SWITCH
C: NOTE
10. Interior Light System
A: WIRING DIAGRAM
B: INSPECTION
1. CHECK DOOR SWITCH.
2. CHECK REAR GATE LATCH SWITCH
3. CHECK TRUNK LID SWITCH
C: NOTE
11. Combination Switch (Light)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. LIGHTING SWITCH
2. DIMMER & PASSING SWITCH
3. TURN SIGNAL SWITCH
4. FRONT FOG LIGHT SWITCH
12. Light Control Sensor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
13. Headlight Assembly
A: REMOVAL
B: INSTALLATION
C: ADJUSTMENT
1. HEADLIGHT BEAM ADJUSTMENT
14. Headlight Bulb
A: REMOVAL
1. HIGH BEAM
2. LOW BEAM
B: INSTALLATION
C: INSPECTION
15. Front Turn Signal Light Bulb
A: REMOVAL
B: INSTALLATION
C: INSPECTION
16. Clearance/Parking Light Bulb
A: REMOVAL
B: INSTALLATION
C: INSPECTION
17. Front Side Marker Light Bulb
A: REMOVAL
B: INSTALLATION
C: INSPECTION
18. Front Fog Light Assembly
A: REMOVAL
B: INSTALLATION
C: ADJUSTMENT
1. FOG LIGHT AIMING
19. Front Fog Light Bulb
A: REMOVAL
B: INSTALLATION
C: INSPECTION
20. Side Turn Signal Light Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
21. Rear Combination Light Assembly
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
C: INSPECTION
22. Tail/Stop Light Bulb
A: REMOVAL
1. SEDAN MODEL
. Rear combination light side
. Rear finisher light side
2. OUTBACK MODEL
. Rear combination light side
. Rear finisher light side
B: INSTALLATION
C: INSPECTION
23. Rear Turn Signal Light Bulb
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
C: INSPECTION
24. Rear Finisher Light Assembly
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
25. Back-up Light Bulb
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
C: INSPECTION
26. License Plate Light
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
C: INSPECTION
27. High-mounted Stop Light
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
C: INSPECTION
28. Spot Map Light
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. SPOT MAP LIGHT BULB
2. SPOT MAP LIGHT SWITCH
3. OVERHEAD CONSOLE ILLUMINATION LIGHT BULB
29. Room Light
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. ROOM LIGHT BULB
2. ROOM LIGHT SWITCH
30. Luggage Room Light
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. LUGGAGE ROOM LIGHT BULB
2. LUGGAGE ROOM LIGHT SWITCH
31. Trunk Room Light
A: REMOVAL
B: INSTALLATION
C: INSPECTION
32. Glove Box Light
A: REMOVAL
B: INSTALLATION
C: INSPECTION
33. Door Step Light
A: REMOVAL
B: INSTALLATION
C: INSPECTION
34. Ignition Switch Illumination
A: REMOVAL
B: INSTALLATION
C: INSPECTION
35. Day Time Running Resistor
A: REMOVAL
B: INSTALLATION
36. Reflex Reflector
A: REMOVAL
B: INSTALLATION
37. Door Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
WIPER AND WASHER SYSTEMS WW
1. General Description
A: SPECIFICATION
B: COMPONENT
1. FRONT WIPER
2. REAR WIPER
3. WASHER TANK
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Wiper and Washer System
A: WIRING DIAGRAM
1. WIPER AND WASHER (FRONT)
2. WIPER AND WASHER (REAR)
B: INSPECTION
C: NOTE
3. Combination Switch (Wiper)
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. INSPECTION OF SWITCH UNIT
2. FRONT WIPER
3. REAR WIPER
4. Wiper Blade
A: REMOVAL
1. FRONT
2. REAR
B: INSTALLATION
C: DISASSEMBLY
1. FRONT
2. REAR
D: ASSEMBLY
1. FRONT
2. REAR
E: INSPECTION
5. Washer Tank and Motor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. WASHER MOTOR
2. WASHER FLUID LEVEL SENSOR
6. Front Wiper Arm
A: REMOVAL
B: INSTALLATION
7. Front Wiper Motor and Link
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Front Washer Nozzle
A: REMOVAL
B: INSTALLATION
C: INSPECTION
D: ADJUSTMENT
9. Rear Wiper Arm
A: REMOVAL
B: INSTALLATION
C: ADJUSTMENT
10. Rear Wiper Motor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
11. Rear Washer
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. VISUAL INSPECTION
2. INSPECTING THE SPRAY POSITION
ENTERTAINMENT ET
1. General Description
A: CAUTION
B: PREPARATION TOOL
1. GENERAL TOOL
2. Audio System
A: WIRING DIAGRAM
1. AUDIO
B: INSPECTION
C: NOTE
3. Navigation System
A: WIRING DIAGRAM
B: INSPECTION
1. CHECK NAVIGATION OPERATION
2. CHECK EACH CONNECTION
. CHECK MICROPHONE, AUX AND REARVIEW CAMERA
. CHECK GPS ANTENNA
. CHECK UART COMMUNICATION
3. CHECK EACH VEHICLE SIGNAL
. CHECK BACK SENSOR
. CHECK IGNITION SWITCH
. CHECK SPEED SENSOR
. CHECK PARKING BRAKE
4. CHECK DVD-ROM
5. MESSAGE LIST
C: NOTE
4. Audio
A: REMOVAL
B: INSTALLATION
5. Front Speaker
A: REMOVAL
1. FRONT SIDE SPEAKER
2. FRONT DOOR SPEAKER
B: INSTALLATION
6. Rear Speaker
A: REMOVAL
B: INSTALLATION
7. Woofer
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
8. Power Amplifier
A: REMOVAL
B: INSTALLATION
9. Antenna
A: REMOVAL
1. RADIO ANTENNA AMPLIFIER
. Sedan model
. OUTBACK model
B: INSTALLATION
C: INSPECTION
1. TYPE A
2. TYPE B
D: REPAIR
10. Noise Suppressor
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
11. Steering Satellite Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
12. Navigation Body
A: REMOVAL
13. GPS Antenna
A: REMOVAL
B: INSTALLATION
14. Rearview Camera System
A: WIRING DIAGRAM
B: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
C: INSTALLATION
D: INSPECTION
E: ADJUSTMENT
1. MARKER ADJUSTMENT MODE
15. Front Accessory Power Supply Socket
A: WIRING DIAGRAM
B: REMOVAL
C: INSTALLATION
16. Rear Accessory Power Supply Socket
A: WIRING DIAGRAM
B: REMOVAL
C: INSTALLATION
17. AUX Input Terminal
A: REMOVAL
1. AUX INPUT TERMINAL
2. AUX TERMINAL HARNESS
B: INSTALLATION
COMMUNICATION SYSTEM COM
1. General Description
A: COMPONENT
B: CAUTION
C: PREPARATION TOOL
1. GENERAL TOOL
2. Relay and Fuse
A: LOCATION
B: INSPECTION
1. CHECK FUSE.
2. CHECK RELAY
3. Horn System
A: WIRING DIAGRAM
B: INSPECTION
C: NOTE
4. Horn
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CHECK HORN ASSEMBLY.
5. Horn Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CHECK HORN SWITCH.
2. CHECK ROLL CONNECTOR.
GLASS/WINDOWS/MIRRORS GW
1. General Description
A: COMPONENT
1. FIXED GLASS (SEDAN MODEL)
2. FIXED GLASS (OUTBACK MODEL)
3. FRONT DOOR GLASS
4. REAR DOOR GLASS
5. MIRROR
B: CAUTION
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Relay and Fuse
A: LOCATION
B: INSPECTION
1. CHECK FUSE.
2. CHECK RELAY
3. Power Window System
A: WIRING DIAGRAM
B: INSPECTION
C: OPERATION
1. RESET OPERATION A
2. RESET OPERATION B
D: NOTE
4. Power Window Control Switch
A: REMOVAL
1. MAIN SWITCH
2. SUB-SWITCH
B: INSTALLATION
C: INSPECTION
1. MAIN SWITCH
. Driver’s side
. Except for driver’s seat
2. SUB-SWITCH
5. Front Door Glass
A: REMOVAL
B: INSTALLATION
6. Front Regulator and Motor Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Remote Control Mirror System
A: WIRING DIAGRAM
B: INSPECTION
1. SYMPTOM CHART
C: NOTE
8. Scalp Cap
A: REPLACEMENT
1. MODEL WITHOUT RETRACTABLE MIRROR
2. MODEL WITH RETRACTABLE MIRROR
9. Outer Mirror Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Outer Mirror
A: REPLACEMENT
1. MODEL WITHOUT RETRACTABLE MIRROR
2. MODEL WITH RETRACTABLE MIRROR
11. Remote Control Mirror Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
12. Rear Door Glass
A: REMOVAL
B: INSTALLATION
13. Rear Regulator and Motor Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
14. Windshield Glass
A: REMOVAL
1. USING WINDSHIELD GLASS KNIFE
2. USING PIANO WIRE
B: INSTALLATION
15. Rear Gate Glass
A: REMOVAL
B: INSTALLATION
16. Rear Window Glass
A: REMOVAL
B: INSTALLATION
17. Rear Window Defogger System
A: WIRING DIAGRAM
B: INSPECTION
1. CHECK SYSTEM
2. CHECK WITH SUBARU SELECT MONITOR
3. HEAT WIRE INSPECTION
C: REPAIR
18. Rear Quarter Glass
A: REMOVAL
B: INSTALLATION
19. Rearview Mirror
A: REMOVAL
B: INSTALLATION
C: INSPECTION
20. Wiper Deicer System
A: WIRING DIAGRAM
B: INSPECTION
1. CHECK SYSTEM
2. CHECK WITH SUBARU SELECT MONITOR
3. HEAT WIRE INSPECTION
C: REPAIR
BODY STRUCTURE BS
1. General Description
A: SPECIFICATION
INSTRUMENTATION/DRIVER INFO IDI
1. General Description
A: SPECIFICATION
B: CAUTION
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Relay and Fuse
A: LOCATION
B: INSPECTION
1. CHECK FUSE.
3. Combination Meter System
A: WIRING DIAGRAM
B: ELECTRICAL SPECIFICATION
1. COMBINATION METER TERMINAL ARRANGEMENT
C: OPERATION
1. SELF-DIAGNOSIS DISPLAY MODE
2. DTC DISPLAY MODE
3. DEALER CUSTOMIZE MODE
D: INSPECTION
1. SYMPTOM CHART
2. CHECK POWER SUPPLY AND GROUND CIRCUIT
3. CHECK VDC CONTROL MODULE
4. CHECK ENGINE CONTROL MODULE (ECM)
5. CHECK FUEL LEVEL SENSOR
6. CHECK ECO GAUGE
7. CHECK WARNING BUZZER FOR KEY LEFT IN IGNITION
E: NOTE
4. Clock System
A: WIRING DIAGRAM
B: ELECTRICAL SPECIFICATION
1. MULTI DISPLAY TERMINAL ARRANGEMENT
C: INSPECTION
1. SYMPTOM CHART
2. CHECK POWER SUPPLY AND GROUND CIRCUIT.
3. CHECK CLOCK SYSTEM COMMUNICATION CIRCUIT
4. CHECK AMBIENT TEMPERATURE SYSTEM COMMUNICATION CIRCUIT
5. CHECK FUEL ECONOMY SYSTEM COMMUNICATION CIRCUIT.
D: NOTE
5. Combination Meter
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. DISASSEMBLY OF COMBINATION METER ASSEMBLY
2. BULB REPLACEMENT
D: ASSEMBLY
6. Speedometer
A: SPECIFICATION
7. Tachometer
A: SPECIFICATION
8. Fuel Gauge
A: SPECIFICATION
9. ECO Gauge
A: SPECIFICATION
10. Multi Display
A: REMOVAL
B: INSTALLATION
SEATS SE
1. General Description
A: COMPONENT
1. FRONT SEAT
2. REAR SEAT (SEDAN MODEL)
3. REAR SEAT (OUTBACK MODEL)
B: CAUTION
C: PREPARATION TOOL
1. GENERAL TOOL
2. Front Seat
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
1. DRIVER SEAT (MANUAL SEAT)
2. DRIVER SEAT (POWER SEAT)
3. PASSENGER’S SEAT
D: ASSEMBLY
E: INSPECTION
1. SEAT COVER
2. FLAT MAT HOOK
3. Rear Seat
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
3. WIRE CABLE
Release lever cable (sedan model)
Reclining cable (OUTBACK model)
Backrest cable (OUTBACK model)
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
4. Power Seat System
A: REMOVAL
1. POWER SEAT SWITCH
2. LUMBAR SWITCH
B: INSTALLATION
C: INSPECTION
1. WIRING DIAGRAM
2. TROUBLE SYMPTOM
3. CHECK POWER SEAT SWITCH
4. CHECK LUMBAR SWITCH
5. ALL FUNCTIONS DO NOT OPERATE.
6. SOME MOTORS DO NOT OPERATE.
5. Seat Heater System
A: REMOVAL
1. SEAT HEATER UNIT
2. SEAT HEATER SWITCH
3. SEAT HEATER RELAY AND FUSE
B: INSTALLATION
C: INSPECTION
1. WIRING DIAGRAM
2. DIAGNOSTIC CHART
3. CHECK SEAT HEATER FUSE
4. CHECK SEAT HEATER RELAY
5. CHECK SEAT HEATER SWITCH
6. CHECK POWER SUPPLY AND GROUND CIRCUIT
SECURITY AND LOCKS SL
1. General Description
A: COMPONENT
1. DOOR LOCK ASSEMBLY
2. REAR GATE LOCK AND TRUNK LID LOCK
3. FRONT HOOD LOCK AND REMOTE OPENERS
4. KEYLESS ENTRY SYSTEM
5. SECURITY SYSTEM
B: CAUTION
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Relay and Fuse
A: LOCATION
B: INSPECTION
1. CHECK FUSE.
3. Door Lock Control System
A: WIRING DIAGRAM
B: ELECTRICAL SPECIFICATION
1. BODY INTEGRATED UNIT
C: INSPECTION
1. SYMPTOM CHART
2. CHECK POWER SUPPLY AND GROUND CIRCUIT
3. CHECK DOOR LOCK SWITCH
4. CHECK REAR GATE/TRUNK OPENER BUTTON SWITCH CIRCUIT
5. CHECK DOOR LOCK ACTUATOR AND CIRCUIT.
4. Keyless Entry System
A: WIRING DIAGRAM
B: ELECTRICAL SPECIFICATION
1. KEYLESS ENTRY CONTROL MODULE
2. BODY INTEGRATED UNIT
C: INSPECTION
1. SYMPTOM CHART
2. CHECK KEYLESS TRANSMITTER BATTERY AND FUNCTION
3. CHECK KEYLESS ENTRY CONTROL MODULE
4. CHECK BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT
5. CHECK DOOR SWITCH
6. CHECK KEY WARNING SWITCH.
7. CHECK ROOM LIGHT OPERATION
8. CHECK HAZARD LIGHT OPERATION
9. CHECK KEYLESS BUZZER
10. CHECK DOOR LOCK SWITCH
11. CHECK IGNITION SWITCH ILLUMINATION
5. Security System
A: WIRING DIAGRAM
B: ELECTRICAL SPECIFICATION
C: INSPECTION
1. BASIC DIAGNOSTIC PROCEDURE
2. CHECK SECURITY SYSTEM CONDITION MEMORY
3. SECURITY SYSTEM ON/OFF SETTING
4. CHECK DOOR SWITCH
5. CHECK SECURITY INDICATOR LIGHT CIRCUIT
6. CHECK HORN
7. CHECK HAZARD LIGHT OPERATION
8. CHECK IGNITION SWITCH CIRCUIT
6. Front Inner Remote
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Front Outer Handle
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Front Door Latch and Door Lock Actuator Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. FRONT DOOR LATCH
2. FRONT DOOR LOCK ACTUATOR
9. Rear Inner Remote
A: REMOVAL
B: INSTALLATION
C: INSPECTION
10. Rear Outer Handle
A: REMOVAL
B: INSTALLATION
C: INSPECTION
11. Rear Door Latch and Door Lock Actuator Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. REAR DOOR LATCH
2. REAR DOOR LOCK ACTUATOR
12. Rear Gate Opener Button
A: REMOVAL
B: INSTALLATION
C: INSPECTION
13. Trunk Opener Switch
A: REMOVAL
1. TRUNK OPENER SWITCH
2. TRUNK OPENER CANCEL BUTTON
B: INSTALLATION
C: INSPECTION
1. TRUNK OPENER SWITCH
2. TRUNK OPENER CANCEL BUTTON
14. Rear Gate Latch and Actuator Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. REAR GATE LATCH
2. LOCK ACTUATOR
15. Trunk Lid Latch and Actuator Assembly
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. TRUNK LID LATCH
2. LOCK ACTUATOR
16. Front Hood Lock Assembly
A: REMOVAL
B: INSTALLATION
C: ADJUSTMENT
D: INSPECTION
17. Remote Openers
A: REMOVAL
1. FRONT HOOD OPENER
2. FUEL FLAP OPENER
B: INSTALLATION
C: INSPECTION
18. Ignition Key Lock
A: REPLACEMENT
B: INSPECTION
19. Key Lock Cylinders
A: REPLACEMENT
1. FRONT DOOR
2. TRUNK LID
3. GLOVE BOX LID
20. Security Control Module
A: REMOVAL
B: INSTALLATION
21. Impact Sensor
A: REMOVAL
B: INSTALLATION
C: OPERATION
1. IMPACT SENSOR SETTING USING SUBARU SELECT MONITOR
D: ADJUSTMENT
1. CHECK IMPACT SENSOR
2. IMPACT SENSITIVITY ADJUSTMENT
22. Keyless Entry Control Module
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
23. Keyless Buzzer
A: REMOVAL
B: INSTALLATION
C: INSPECTION
24. Body Integrated Unit
A: REMOVAL
B: INSTALLATION
25. Keyless Transmitter
A: REMOVAL
1. KEYLESS TRANSMITTER BATTERY
B: INSTALLATION
1. KEYLESS TRANSMITTER BATTERY
C: INSPECTION
1. KEYLESS TRANSMITTER BATTERY
D: REPLACEMENT
1. REGISTRATION OF KEYLESS TRANSMITTER WITH SUBARU SELECT MONITOR
26. Transmitter
A: REMOVAL
1. TRANSMITTER BATTERY
B: INSTALLATION
1. TRANSMITTER BATTERY
C: INSPECTION
1. TRANSMITTER BATTERY
D: REPLACEMENT
1. REGISTRATION OF KEYLESS TRANSMITTER WITH SUBARU SELECT MONITOR
27. Immobilizer Control Module
A: NOTE
28. Immobilizer Antenna
A: REMOVAL
B: INSTALLATION
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) SR
1. General Description
A: COMPONENT
B: CAUTION
C: PREPARATION TOOL
1. GENERAL TOOL
2. Relay and Fuse
A: LOCATION
B: INSPECTION
1. CHECK FUSE.
3. Sunroof Control System
A: WIRING DIAGRAM
B: INSPECTION
C: OPERATION
1. INITIALIZE OPERATION
D: NOTE
4. Glass Lid
A: REMOVAL
B: INSTALLATION
C: ADJUSTMENT
D: FORCED DRIVE
5. Sunroof Assembly
A: REMOVAL
B: INSTALLATION
C: DISASSEMBLY
D: ASSEMBLY
6. Sunroof Motor
A: REMOVAL
B: INSTALLATION
C: INSPECTION
7. Sunroof Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Sunshade
A: REMOVAL
B: INSTALLATION
C: INSPECTION
1. CHECK FOR MOVING LOAD OF SUNSHADE
EXTERIOR/INTERIOR TRIM EI
1. General Description
A: COMPONENT
1. FRONT UNDER COVER
2. FLOOR UNDER PROTECTOR
3. FUEL TANK PROTECTOR
4. FRONT HOOD GRILLE
5. FRONT BUMPER
6. REAR BUMPER
7. MUD GUARD
8. COWL PANEL
9. SIDE SILL SPOILER
10. ROOF MOLDING
11. ROOF RAIL
12. TRUNK LID GARNISH
13. REAR GATE GARNISH
14. DOOR TRIM
15. CONSOLE BOX
16. INSTRUMENT PANEL
17. INNER TRIM
18. REAR GATE TRIM
19. ROOF TRIM
20. ROOM INNER PARTS
21. HEAT SHIELD COVER
B: PREPARATION TOOL
2. Front Grille
A: REMOVAL
B: INSTALLATION
3. Front Hood Grille
A: REMOVAL
B: INSTALLATION
4. Cowl Panel
A: REMOVAL
B: INSTALLATION
5. Front Under Cover
A: REMOVAL
B: INSTALLATION
6. Floor Under Protector
A: REMOVAL
B: INSTALLATION
7. Fuel Tank Protector
A: REMOVAL
B: INSTALLATION
8. Mud Guard
A: REMOVAL
B: INSTALLATION
9. Front Bumper
A: REMOVAL
B: INSTALLATION
C: REPAIR
1. COATING METHOD FOR PP BUMPER
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER
10. Rear Bumper
A: REMOVAL
B: INSTALLATION
C: REPAIR
11. Side Sill Spoiler
A: REMOVAL
B: INSTALLATION
12. Roof Molding
A: REMOVAL
B: INSTALLATION
13. Roof Rail
A: REMOVAL
B: INSTALLATION
14. Door Trim
A: REMOVAL
1. FRONT DOOR
2. REAR DOOR
B: INSTALLATION
15. Instrument Panel Lower Cover
A: REMOVAL
B: INSTALLATION
16. Glove Box
A: REMOVAL
B: INSTALLATION
17. Center Console
A: REMOVAL
1. CENTER PANEL ASSY
2. CONSOLE FRONT COVER
MT model
AT model
B: INSTALLATION
18. Console Box
A: REMOVAL
B: INSTALLATION
19. Instrument Panel Assembly
A: REMOVAL
B: INSTALLATION
20. Lower Inner Trim
A: REMOVAL
B: INSTALLATION
21. Upper Inner Trim
A: REMOVAL
B: INSTALLATION
22. Rear Quarter Trim
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
23. Rear Shelf Trim
A: REMOVAL
B: INSTALLATION
24. Trunk Room Trim
A: REMOVAL
1. TRUNK LID TRIM
2. TRUNK ROOM TRIM
B: INSTALLATION
25. Sun Visor
A: REMOVAL
B: INSTALLATION
26. Assist Grip
A: REMOVAL
B: INSTALLATION
27. Roof Trim
A: REMOVAL
1. SEDAN MODEL
2. OUTBACK MODEL
B: INSTALLATION
28. Rear Gate Trim
A: REMOVAL
B: INSTALLATION
29. Floor Mat
A: REMOVAL
B: INSTALLATION
30. Trunk Lid Garnish
A: REMOVAL
B: INSTALLATION
31. Rear Gate Garnish
A: REMOVAL
B: INSTALLATION
32. Heat Shield Cover
A: REMOVAL
1. FRONT HEAT SHIELD COVER
2. CENTER HEAT SHIELD COVER
3. REAR HEAT SHIELD COVER
B: INSTALLATION
33. Ornament
A: INSTALLATION
1. LETTER MARK
EXTERIOR BODY PANELS EB
1. General Description
A: SPECIFICATION
B: COMPONENT
1. FRONT HOOD
2. FRONT FENDER
3. FRONT DOOR
4. REAR DOOR
5. TRUNK LID PANEL
6. REAR GATE
C: CAUTION
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
2. Front Hood
A: REMOVAL
1. FRONT HOOD INSULATOR
2. FRONT HOOD SEAL
3. FRONT HOOD DAMPER
4. FRONT HOOD HINGE
5. FRONT HOOD PANEL
B: INSTALLATION
C: ADJUSTMENT
D: DISPOSAL
3. Front Fender
A: REMOVAL
B: INSTALLATION
4. Front Door
A: REMOVAL
B: INSTALLATION
C: ADJUSTMENT
5. Front Sealing Cover
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Rear Door
A: REMOVAL
B: INSTALLATION
C: ADJUSTMENT
7. Rear Sealing Cover
A: REMOVAL
B: INSTALLATION
C: INSPECTION
8. Door Sash Tape
A: REMOVAL
1. FRONT DOOR
2. REAR DOOR
B: INSTALLATION
9. Trunk Lid
A: REMOVAL
1. TRUNK LID DAMPER STAY
2. TRUNK LID HINGE
3. TRUNK LID PANEL
B: INSTALLATION
C: ADJUSTMENT
10. Rear Gate
A: REMOVAL
1. REAR GATE PANEL
2. REAR GATE DAMPER STAY
B: INSTALLATION
1. REAR GATE PANEL
2. REAR GATE DAMPER STAY
C: ADJUSTMENT
D: DISPOSAL
1. REAR GATE DAMPER STAY
11. Protector Tape
A: INSTALLATION
1. REAR DOOR PROTECTOR (OUTBACK MODEL)
2. REAR QUARTER PROTECTOR
CRUISE CONTROL SYSTEM CC
1. General Description
A: COMPONENT
B: CAUTION
C: PREPARATION TOOL
2. Relay and Fuse
A: LOCATION
B: INSPECTION
1. CHECK FUSE.
3. Cruise Control System
A: WIRING DIAGRAM
B: INSPECTION
C: NOTE
4. Cruise Control Module
A: NOTE
B: REMOVAL
C: INSTALLATION
5. Cruise Control Command Switch
A: REMOVAL
B: INSTALLATION
C: INSPECTION
6. Combination Meter
A: NOTE
7. Stop Light & Brake Switch
A: NOTE
8. Clutch Switch
A: NOTE
9. Inhibitor Switch
A: NOTE
1. CVT MODEL
2. 5AT MODEL
10. Transmission Control Module (TCM)
A: NOTE
11. Neutral Position Switch
A: NOTE
CRUISE CONTROL SYSTEM (DIAGNOSTICS) CC(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. General Description
A: CAUTION
B: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
C: INSPECTION
3. Electrical Component Location
A: LOCATION
4. Engine Control Module (ECM) I/O Signal
A: ELECTRICAL SPECIFICATION
B: WIRING DIAGRAM
5. Subaru Select Monitor
A: OPERATION
1. GENERAL DESCRIPTION
2. BASIC OPERATION
6. Read Cancel Code
A: OPERATION
7. Real-time Diagnosis
A: OPERATION
8. Diagnostics with Phenomenon
A: DIAGNOSTIC PROCEDURE WITH PHENOMENON
B: CHECK CRUISE INDICATOR LIGHT AND CRUISE SET INDICATOR LIGHT
9. List of Cancel Code
A: LIST
10. Diagnostic Procedure with Cancel Code
A: 11
B: 12
C: 13
D: 14
E: 15
F: 16
G: 21
H: 22
I: 24
J: 25
K: 31
L: 32
M: 34
N: 35
O: 41
P: 43
Q: 44
R: 45
S: 49
T: 61
U: 62
V: 63
W: 64
X: 65
Y: 66
IMMOBILIZER (DIAGNOSTICS) IM(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. General Description
A: CAUTION
B: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
3. Electrical Component Location
A: LOCATION
4. Immobilizer Control Module I/ O Signal
A: WIRING DIAGRAM
1. IMMOBILIZER
5. Subaru Select Monitor
A: OPERATION
1. HOW TO USE THE SUBARU SELECT MONITOR
2. READ DIAGNOSTIC TROUBLE CODE (DTC) FOR ENGINE AND BODY INTEGRATED UNIT
3. COMMUNICATION LINE CHECK
6. Read Diagnostic Trouble Code (DTC)
A: OPERATION
1. ECM
2. BODY INTEGRATED UNIT
7. Clear Memory Mode
A: OPERATION
1. ECM
2. BODY INTEGRATED UNIT
8. Diagnostics Chart for Security Indicator Light
A: INSPECTION
1. CHECK SECURITY INDICATOR LIGHT CIRCUIT
2. CHECK KEY SWITCH CIRCUIT
9. List of Diagnostic Trouble Code (DTC)
A: LIST
1. ECM
2. BODY INTEGRATED UNIT
10. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC P0513 INCORRECT IMMOBILIZER KEY
B: DTC P1570 ANTENNA
C: DTC P1571 REFERENCE CODE INCOMPATIBILITY
D: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)
E: DTC P1574 KEY COMMUNICATION FAILURE
F: DTC P1576 EGI CONTROL MODULE EEPROM
G: DTC P1577 IMM CONTROL MODULE EEPROM
H: DTC P1578 METER FAILURE
I: DTC B1401 M COLLATION NG
J: DTC B1402 IMMOBILIZER KEY COLLATION NG
K: DTC B1403 E/G REQUEST NG
L: DTC B1405 SCU COLLATION NG
M: DTC B1406 SCU_EEPROM_NG
LAN SYSTEM (DIAGNOSTICS) LAN(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. Check List for Interview
A: CHECK
1. DISPLAY STATUS OF FAILURE INFORMATION
2. DISPLAY STATUS IN THE COMBINATION METER
3. CONDITIONS UNDER WHICH TROUBLE OCCURS
3. General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG”
2. LAN SYSTEM
B: INSPECTION
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
4. Electrical Component Location
A: LOCATION
5. Control Module I/O Signal
A: ELECTRICAL SPECIFICATION
B: WIRING DIAGRAM
6. Subaru Select Monitor
A: OPERATION
7. Read Diagnostic Trouble Code (DTC)
A: OPERATION
8. Clear Memory Mode
A: OPERATION
9. CAN Communication Circuit Check
A: PROCEDURE
B: LIST
C: INSPECTION
1. GROUND SHORT INSPECTION
2. BATTERY SHORT INSPECTION
3. 56 - 64 W
4. 55 W OR LESS
5. 65 W OR MORE
6. 56 - 64 W (TCM)
7. RELATED LINES 56 - 64 W (STEERING ANGLE SENSOR)
8. 56 - 64 W (A/C CM)
9. 56 - 64 W (ELECTRONIC PARKING CM)
10. 56 - 64 W (COMBINATION METER)
11. 56 - 64 W (SECURITY CM)
10. List of Diagnostic Trouble Code (DTC)
A: LIST
1. DTC TABLE
11. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
B: DTC U1201 CAN-HS COUNTER ABNORMAL
C: DTC U1202 CAN-HS BUS OFF
D: DTC U1211 CAN-HS ECM DATA ABNORMAL
E: DTC U1212 CAN-HS TCM DATA ABNORMAL
F: DTC U1213 CAN-HS VDC DATA ABNORMAL
G: DTC U1219 CAN-HS EPB DATA ABNORMAL
H: DTC U121A CAN-HS METER UNIT DATA ABNORMAL
I: DTC U121B CAN-HS A/C DATA ABNORMAL
J: DTC U121C CAN-HS SCU DATA ABNORMAL
K: DTC U1221 CAN-HS ECM NO-RECEIVE DATA
L: DTC U1222 CAN-HS TCM NO-RECEIVE DATA
M: DTC U1223 CAN-HS VDC NO-RECEIVE DATA
N: DTC U1229 CAN-HS EPB NO-RECEIVE DATA
O: DTC U122A CAN-HS METER NO-RECEIVE DATA
P: DTC U122B CAN-HS A/C NO-RECEIVE DATA
Q: DTC U122C CAN-HS SCU NO-RECEIVE DATA
12. General Diagnostic Table
A: INSPECTION
BODY CONTROL SYSTEM (DIAGNOSTICS) BC(diag)
1. Basic Diagnostic Procedure
A: PROCEDURE
2. Check List for Interview
A: CHECK
3. General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG”
B: INSPECTION
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
4. Electrical Component Location
A: LOCATION
5. Control Module I/O Signal
A: ELECTRICAL SPECIFICATION
6. Read Diagnostic Trouble Code (DTC)
A: OPERATION
7. Clear Memory Mode
A: OPERATION
8. Read Current Data
A: OPERATION
B: LIST
9. User Customizing
A: OPERATION
10. Registration Body Integrated Unit
A: OPERATION
1. CONFIRMATION OF CURRENT SETTING
2. REGISTRATION BODY INTEGRATED UNIT (FUNCTION SETTING)
3. DESTINATION SETTING
11. Function Check
A: OPERATION
12. List of Diagnostic Trouble Code (DTC)
A: LIST
13. Diagnostic Procedure with Diagnostic Trouble Code (DTC)
A: DTC B1100 INTEG. UNIT SYSTEM ERROR
B: DTC B1101 BATT P/SUPPLY MALFUNCTION CONT
C: DTC B1102 BATT P/SUPPLY MALFUNCTION BACKUP
D: DTC B1103 IGNITION POWER FAILURE
E: DTC B1104 ACC POWER FAILURE
F: DTC B1106 SHIFT LOCK CIRCUIT FAILURE
G: DTC B1401 M COLLATION NG
H: DTC B1402 IMMOBILIZER KEY COLLATION NG
I: DTC B1403 E/G REQUEST NG
J: DTC B1405 SCU COLLATION NG
K: DTC B1406 SCU_EEPROM_NG
L: DTC B1500 KEYLESS UART COM. MALFUNCTION
14. General Diagnostic Table
A: INSPECTION
WIRING SYSTEM SECTION
WIRING SYSTEM WI
1. Basic Diagnostic Procedure
A: BASIC PROCEDURES
1. GENERAL DESCRIPTION
2. IDENTIFICATION OF TROUBLE SYMPTOM
3. PROBABLE CAUSE OF TROUBLE
4. LOCATION AND REPAIR OF TROUBLE
5. SYSTEM OPERATION CHECK
B: BASIC INSPECTION
1. VOLTAGE MEASUREMENT
2. CIRCUIT CONTINUITY CHECKS
3. HOW TO DETERMINE AN OPEN CIRCUIT
4. HOW TO DETERMINE A SHORT CIRCUIT
C: HOW TO READ WIRING DIAGRAMS
1. WIRING DIAGRAM
D: SYMBOLS IN WIRING DIAGRAMS
1. RELAY
2. CONNECTOR 1
3. WIRING CONNECTION
4. FUSE NO. & RATING
5. CONNECTOR 2
6. CONNECTOR SKETCH
7. GROUND
8. DIODE
9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS
10. SYMBOLS OF WIRE CONNECTION AND CROSSING
11. POWER SUPPLY CIRCUIT
12. CLASSIFICATION BY SPECIFICATION
13. TWISTED PAIR LINE
E: CONNECTOR SYMBOL IN WIRING HARNESS
F: ABBREVIATION IN WIRING DIAGRAMS
2. Working Precautions
A: PRECAUTIONS WHEN WORKING WITH THE PARTS MOUNTED ON THE VEHICLE
B: PRECAUTIONS IN TROUBLE DIAGNOSIS AND REPAIR OF ELECTRIC PARTS
3. Power Supply Circuit
A: WIRING DIAGRAM
4. Ground Circuit
A: WIRING DIAGRAM
1. CHASSIS GROUND
2. ENGINE GROUND (2.5 L NON-TURBO MODEL)
3. ENGINE GROUND (2.5 L TURBO MODEL)
4. ENGINE GROUND (3.6 L MODEL)
5. TRANSMISSION GROUND (AT MODEL)
6. TRANSMISSION GROUND (CVT MODEL)
5. Airbag System
A: WIRING DIAGRAM
6. Air Conditioning System
A: WIRING DIAGRAM
1. MANUAL A/C
2. AUTO A/C
7. AT Control System
A: WIRING DIAGRAM
8. AT Shift Lock Control System
A: WIRING DIAGRAM
9. Audio System
A: WIRING DIAGRAM
1. NORMAL AUDIO
2. PREMIUM AUDIO
10. Back-up Light System
A: WIRING DIAGRAM
11. CAN Communication System
A: WIRING DIAGRAM
12. Charging System
A: WIRING DIAGRAM
13. Clearance Light and Illumination Light System
A: WIRING DIAGRAM
14. Clock System
A: WIRING DIAGRAM
15. Combination Meter System
A: WIRING DIAGRAM
16. Coolant Temperature System
A: WIRING DIAGRAM
17. Cruise Control System
A: WIRING DIAGRAM
1. 2.5 L NON-TURBO MODEL
2. EXCEPT FOR 2.5 L NON-TURBO MODEL
18. CVT Control System
A: WIRING DIAGRAM
19. Engine Electrical System
A: WIRING DIAGRAM
1. 2.5 L NON-TURBO MODEL
2. 2.5 L TURBO MODEL
3. 3.6 L MODEL
20. Front Accessory Power Supply Socket System
A: WIRING DIAGRAM
21. Front Fog Light System
A: WIRING DIAGRAM
22. Front Wiper and Washer System
A: WIRING DIAGRAM
23. Fuel Gauge System
A: WIRING DIAGRAM
24. Headlight System
A: WIRING DIAGRAM
25. Horn System
A: WIRING DIAGRAM
26. Immobilizer System
A: WIRING DIAGRAM
27. Interior Light System
A: WIRING DIAGRAM
28. Keyless Entry System
A: WIRING DIAGRAM
29. Navigation System
A: WIRING DIAGRAM
30. Occupant Detection System
A: WIRING DIAGRAM
31. Oil Pressure Warning Light System
A: WIRING DIAGRAM
32. Parking Brake / Brake Fluid Level Warning Light System
A: WIRING DIAGRAM
33. Power Seat System
A: WIRING DIAGRAM
34. Power Window System
A: WIRING DIAGRAM
1. WITHOUT DRIVER’S SEAT AUTO UP FUNCTION
2. WITH DRIVER’S SEAT AUTO UP FUNCTION
35. Radiator Fan System
A: WIRING DIAGRAM
1. 2.5 L NON-TURBO MODEL
2. 2.5 L TURBO MODEL
3. 3.6 L MODEL
36. Rear Accessory Power Supply Socket System
A: WIRING DIAGRAM
37. Rear Defogger System
A: WIRING DIAGRAM
38. Rearview Camera System
A: WIRING DIAGRAM
1. SEDAN MODEL
2. OUTBACK MODEL
39. Rearview Mirror System
A: WIRING DIAGRAM
40. Rear Wiper and Washer System
A: WIRING DIAGRAM
41. Remote Control Mirror System
A: WIRING DIAGRAM
1. WITHOUT RETRACTABLE MIRROR
2. WITH RETRACTABLE MIRROR
42. Remote Engine Start System
A: WIRING DIAGRAM
43. Seat Belt Warning System
A: WIRING DIAGRAM
1. MANUAL SEAT MODEL
2. MODEL WITH POWER SEATS
44. Seat Heater System
A: WIRING DIAGRAM
1. MANUAL SEAT MODEL
2. MODEL WITH POWER SEATS
45. Security System
A: WIRING DIAGRAM
46. Speedometer System
A: WIRING DIAGRAM
47. Starter System
A: WIRING DIAGRAM
1. 2.5 L NON-TURBO MODEL
2. 2.5 L TURBO MODEL
3. 3.6 L MODEL
48. Stop Light System
A: WIRING DIAGRAM
49. Sunroof Control System
A: WIRING DIAGRAM
50. Tire Pressure Monitoring System
A: WIRING DIAGRAM
51. Turn Signal Light and Hazard Light System
A: WIRING DIAGRAM
52. Vehicle Dynamics Control System
A: WIRING DIAGRAM
53. Wiper Deicer System
A: WIRING DIAGRAM
54. Harness Components Location
A: LOCATION
1. SEDAN MODEL
2. OUTBACK MODEL
55. Front Wiring Harness
A: LOCATION
56. Bulkhead Wiring Harness (In Engine Compartment)
A: LOCATION
1. 2.5 L NON-TURBO MODEL
2. 2.5 L TURBO MODEL
3. 3.6 L MODEL
57. Bulkhead Wiring Harness (In Compartment)
A: LOCATION
1. 2.5 L NON-TURBO MODEL
2. 2.5 L TURBO MODEL
3. 3.6 L MODEL
58. Engine Wiring Harness and Transmission Cord
A: LOCATION
1. 2.5 L NON-TURBO MODEL
2. 2.5 L TURBO MODEL
3. 3.6 L MODEL
59. Instrument Panel Wiring Harness
A: LOCATION
60. Rear Wiring Harness
A: LOCATION
1. SEDAN MODEL
2. OUTBACK MODEL
61. Door Cord
A: LOCATION
62. Rear Wiring Harness and Trunk Lid Cord
A: LOCATION
63. Rear Wiring Harness and Rear Gate Cord
A: LOCATION
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2010 SUBARU LEGACY SERVICE MANUAL

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10LE_US.book

1 ページ

2015年12月24日 木曜日 午後5時18分

2010 LEGACY SERVICE MANUAL

QUICK REFERENCE INDEX

GENERAL INFORMATION SECTION

This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of 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.

FOREWORD

FW

HOW TO USE THIS MANUALS

HU

SPECIFICATIONS

SPC

PRECAUTION

PC

NOTE

NT

IDENTIFICATION

ID

RECOMMENDED MATERIALS

RM

PRE-DELIVERY INSPECTION

PI

PERIODIC MAINTENANCE SERVICES

PM

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD.

G2460BE1

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FOREWORD

FW 1.

Page Foreword ....................................................................................................2

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Foreword FOREWORD

1. Foreword A: FOREWORD These manuals are used when performing maintenance, repair or diagnosis of Subaru LEGACY. Applicable model: 2010MY BM*****, BR***** The manuals contain the latest information at the time of publication. Changes in the specifications, methods, etc. may be made without notice.

FW-2

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HOW TO USE THIS MANUALS

HU 1.

Page How to Use This Manuals ..........................................................................2

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How to Use This Manuals HOW TO USE THIS MANUALS

1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each component. The specification, maintenance and other information for the components are included, and the diagnostic information has also been added where necessary.

2. CONTENTS The first page has an index with tabs.

HU-2

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How to Use This Manuals HOW TO USE THIS MANUALS

3. COMPONENT Illustrations are provided for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order parts, refer to parts catalogue. Example:

(7)

(5)

(5)

T6

T10

(8) (20)

(1)

T1

T3

(4)

(2) T8

T2

(3) (6)

T3

(21)

T2

(1)

T5

T3

T2 T3

(2)

T4 (4)

(4)

(3)

(10) (11)

(11) (10)

(9)

(12) (22) (23) (16) (14)

(9)

(6)

T3

(18) T1

(13) (15)

T2

(17) (19)

T6 (4)

(3) (7)

T4

(10) (4)

(15)

T2 T11

T5

(22)

T6

(3)

(12)

(35)

T4

(8) (10) (23) (14)

T2

T5

(27)

T2

(34) T3

(26)

(24) (25)

T7 (24)

(36)

(25)

(13)

(31) (30)

T2

T5 (29)

(10) (17)

(16)

(37) (32)

(28)

(18) T3

(33)

T4 T1

: Selective part : Replacement part

T1 (21)

: Sealing point : Should be lubricated with oil.

(20) T9

: Should be lubricated with grease.

(19) T1

,

T2

....

: Tightening torque

HU-00017

HU-3

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How to Use This Manuals HOW TO USE THIS MANUALS

4. DEFINITION OF “NOTE”, “CAUTION” AND “WARNING” • NOTE: describes supplementary explanations for efficient operation. • CAUTION: describes particular items to be followed and items to be prohibited to avoid vehicle or parts damage. • WARNING: describes items to be strictly prohibited to avoid serious injury to the person doing the work or people in the area, and items to be strictly followed to avoid any deficiency or accident.

5. SPECIFICATION If necessary, specifications are also included.

6. INSPECTION Inspections to be carried out before and after maintenance are included.

HU-4

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7. MAINTENANCE • Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also describes the use of special tool, tightening torque, caution for each procedure. • If many serviceable parts are included in one service procedure, appropriate reference is provided for each parts. Example:

15.Main Shaft

(A)

A: REMOVAL

(B)

1) Remove the manual transmission assembly from vehicle.

(C)

11) Tighten the lock nuts to the specified torque using ST1 and ST2. NOTE: Secure the lock nuts in two places after tightening. ST1 498937000 TRANSMISSION HOLDER ST2 499987003 SOCKET WRENCH (35) (E)

(D)

(F)

Tightening torque: 118 N m (12.0 kgf-m, 86.8 ft-lb)

(G)

(H)

ST2

ST1

HU-00020

(A) (B) (C)

Component Process Reference

(D) (E) (F)

Cautions Tool number of special tool Name of special tool

HU-5

(G) (H)

Tightening torque Illustration

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How to Use This Manuals HOW TO USE THIS MANUALS

8. DIAGNOSIS Diagnosis uses step-by-step process to make operations easier.

9. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included. Example:

Tightening torque: 44 N·m (4.5 kgf-m, 33 ft-lb) LIST OF SI UNIT Item Force Mass (Weight) Capacity Torque Rotating speed

SI units N (Newton) kg, g 2, m2 or cm3 N·m rpm

Pressure

kPa (kilopascal)

Power Calorie Fuel consumption rate

W W·h g/kw·h

Conventional unit kgf kg, g 2or cc kgf-m, kgf-cm rpm

Remarks 1 kgf = 9.80655 N

kgf/cm2 mmHg PS cal g/PS·h

1 kgf/cm2 = 98.0655 kPa 1 mmHg = 0.133322 kPa 1 PS = 0.735499 kW 1 kcal = 1.16279 W·h 1 g/PS·h = 1.3596 g/kW·h

1 cc = 1 cm3 = 1 m2 1 kgf-m = 9.80655 N·m

The figure used in these manuals are described in the SI units and conventional units are described in (

HU-6

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10.EXPLANATION OF TERMINOLOGY • LIST OF ABBREVIATIONS AAI A/B ABS A/C A/F ALT APS ASSY AT ATF AVCS AWD BATT BCM BJ CAN CD COMPL CPU DOHC DOJ DTC EBJ ECM EDJ EGI E/G EGR ETC EX F/B Ft FWD GPS HID H/U HVAC

: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :

Air Assist Injection Airbag Anti-lock Brake System Air Conditioner Air Fuel Ratio Generator Accessory Power supply Socket Assembly Automatic Transmission Automatic Transmission Fluid Active Valve Control System All Wheel Drive Battery Brake Control Module Bell Joint Communication Area Network Compact Disc Complete Central Processing Unit Double Overhead Camshaft Double Offset Joint Diagnostic Trouble Code High-efficiency Compact Ball Fixed Joint Engine Control Module High-efficiency Compact Double Offset Joint Electronic Gasoline Injection Engine Exhaust Gas Recirculation Electronic Throttle Control Exhaust Fuse & Joint Box Front Front Wheel Drive Global Positioning System High-Intensity Discharge Hydraulic Unit Heater, Ventilator and Air Conditioner

IG IN INT I/O ISC LAN LH LSD M/B MD MID MFI MP-T MT NA NC NO OP PC PCV P/S PTJ P/W RH Rr SDI SI SOHC SRS ST SW TCS TGV T/M UJ VDC VTD

HU-7

: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :

Ignition Intake Intermittent Input / Output Idle Speed Control Local Area Network LH (Left Hand) Limited Slip Differential Main Fuse & Relay Box Mini Disc Multi Information Display Multi-Point Fuel Injection Multi-Plate Transfer Manual Transmission Natural Aspiration Normal Close (Relay) Normal Open (Relay) Option Parts Personal Computer Positive Crankcase Ventilation Power Steering Pillow Tripod Joint Power Window RH (Right Hand) Rear SUBARU Diagnostic Interface SUBARU Intelligent Single Overhead Camshaft Supplemental Restraint System Special Tool Switch Traction Control System Tumble Generator Valve Transmission Universal joint Vehicle Dynamics Control Variable Torque Distribution

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HU-8

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SPECIFICATIONS

SPC 1. 2.

Page LEGACY .....................................................................................................2 OUTBACK ..................................................................................................6

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LEGACY SPECIFICATIONS

1. LEGACY A: DIMENSION 1. SEDAN MODEL Model Overall length Overall width Overall height (at C.W.) Wheelbase Front Tread Rear Minimum road clearance

2.5 L SOHC non-turbo mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

1,565 (61.6) 1,570 (61.8)

2.5 L DOHC turbo 4,735 (186.4) 1,820 (71.7) 1,505 (59.3) 2,750 (108.3) 1,550 (61.0) 1,555 (61.2) 150 (5.9)

3.6 L DOHC non-turbo

1,565 (61.6) 1,570 (61.8)

B: ENGINE Model

2.5 L SOHC non-turbo

2.5 L DOHC turbo

Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine

Engine type Valve arrangement

Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine

Overhead camshaft

Bore × stroke

mm (in)

Displacement

cm3 (cu in)

Compression ratio Ignition order Idle speed at Park or Neutral position Maximum output Maximum torque

3.6 L DOHC non-turbo

99.5 × 79.0 (3.917 × 3.110) 2,457 (149.9) 8.4

3,630 (221.4) 10.5 1—6—3—2—5—4

650 (MT) 675 (CVT)

700

700

127 (170)/5,600 230 (23.5, 170)/4,000

198 (265)/5,600 350 (35.7, 258)/2,000 — 5,200

191 (256)/6,000 334 (34.1, 247)/4,400

10.0 1—3—2—4 rpm kW (HP)/rpm N·m (kgf-m, ft-lb)/rpm

92.0 × 91.0 (3.622 × 3.583)

C: ELECTRICAL Model Ignition timing (at idling) BTDC Spark plug Type and manufacturer Generator Battery

2.5 L SOHC non-turbo

2.5 L DOHC turbo 15° NGK: SIFR6A11 NGK: SILFR6B8 12 V — 110 A

Type and capacity (5HR) CCA

12 V — 52 AH (75D23R) 490 A

SPC-2

3.6 L DOHC non-turbo NGK: SILFR6C11 12 V — 130 A

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LEGACY SPECIFICATIONS

D: TRANSMISSION 1. MT Model Transmission type Clutch type

2.5 L SOHC non-turbo 6MT DSPD 3.454 1.947 1.296 0.972 0.825 0.695 3.636

2.5 L DOHC turbo 6MT DSPD 3.454 1.947 1.296 0.972 0.780 0.666 3.636

Gear ratio

1st 2nd 3rd 4th 5th 6th Rev.

Reduction gear (Front)

Type of gear Gear ratio

Hypoid 4.111

Hypoid 4.111

Transfer reduction

Type of gear Gear ratio

Helical 1.000

Helical 1.000

Final reduction

Type of gear Gear ratio

Hypoid 4.111

Hypoid 4.111

Reduction gear (Rear)

6MT: 6-forward and 1-reverse speeds with synchromesh for all gears DSPD: Dry Single Plate Diaphragm

2. AT Model

3.6 L DOHC non-turbo 5AT TCC 3.540 2.264 1.471 1.000 0.834 2.370

Transmission type Clutch type 1st 2nd 3rd 4th 5th Rev.

Gear ratio

Reduction gear (Front)

1st reduction

Type of gear Gear ratio

Helical 1.000

Final reduction

Type of gear Gear ratio

Hypoid 3.083

Type of gear Gear ratio

Hypoid 3.083

Reduction gear (Rear)

5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse TCC: Torque Converter Clutch

SPC-3

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LEGACY SPECIFICATIONS

3. CVT Model Transmission type Clutch type Forward Rev.

Change gear ratio

Reduction gear (Front)

2.5 L SOHC non-turbo CVT TCC 3.525 — 0.558 2.358

1st reduction Final reduction

Type of gear Gear ratio Type of gear Gear ratio

Helical 1.000 Hypoid 3.700 1.000 Hypoid 3.700

Transfer reduction ratio Type of gear Gear ratio

Reduction gear (Rear)

TCC: Torque Converter Clutch CVT: Forward continuously variable speed change and 1-reverse

E: STEERING Type Turns, lock to lock Minimum turning diameter

Rack & pinion 2.8 m (ft)

Curb to curb Wall to wall

11.2 (36.7) 11.8 (38.7)

F: SUSPENSION Front REAR

Macpherson strut type suspension Double wishbone type suspension

G: BRAKE Model Service brake system Front REAR Parking brake Brake assist

2.5 L SOHC non-turbo 2.5 L DOHC turbo 3.6 L DOHC non-turbo Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Disc brake Ventilated disc brake Electric mechanical on rear brakes Standard equipment for all vehicles

H: TIRE Model Wheel size Tire size Type

2.5L SOHC non-turbo 16 × 6 1/2JJ 16 × 6 1/2J 17 × 7 1/2J P205/60 R16 91V P215/50 R17 90V

2.5L DOHC turbo

3.6L DOHC non-turbo

18 × 7 1/2J

17 × 7 1/2J

225/45 R18 91W

P225/50 R17 93V

Tubeless, Steel belted radial

SPC-4

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LEGACY SPECIFICATIONS

I:

CAPACITY 2.5L DOHC turbo CVT 6MT 70 (18.5, 15.4)

2.5L SOHC non-turbo

Model

6MT Fuel tank Total capacity (at overhaul) Engine Filling amount of oil engine oil 2 (US qt, Imp qt)

2 (US gal, Imp gal)

3.6L DOHC non-turbo 5AT

2 (US qt, Imp qt)

4.8 (5.1, 4.2)

4.8 (5.1, 4.2)

5.2 (5.5, 4.6)

7.8 (8.2, 6.9)

When replacing engine oil and oil filter

4.2 (4.4, 3.7)

4.2 (4.4, 3.7)

4.3 (4.5, 3.8)

6.5 (6.9, 5.7)

When replacing engine oil only

4.0 (4.2, 3.5)

Transmission gear oil

2 (US qt, Imp qt)

3.7 (3.9, 3.3)

ATF or CVTF

2 (US qt, Imp qt)



Front differential gear oil Rear differential gear oil Power steering fluid Engine coolant

2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt)



6.5 (6.9, 5.7)

SPC-5

— 3.7 (3.9, 3.3) 12.0 — 12.5 (12.7 — 13.2, — 10.6 — 11.0) 1.4 (1.5, 1.2) — 0.8 (0.8, 0.7) 0.7 (0.7, 0.6) 6.4 (6.8, 5.6) 6.5 (6.9, 5.7)

6.3 (6.7, 5.5) — 9.8 (10.4, 8.6) 1.4 (1.5, 1.2)

6.5 (6.9, 5.7)

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OUTBACK SPECIFICATIONS

2. OUTBACK A: DIMENSION 1. OUTBACK MODEL Model Overall length Overall width Overall height (at C.W.) Wheelbase Front Tread REAR Minimum road clearance *1:

2.5L SOHC non-turbo mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

3.6L DOHC non-turbo

4,780 (188.2) 1,820 (71.7) 1,680 (66.1), 1,670 (65.7)*1 2,740 (107.9) 1,550 (61.0) 1,550 (61.0) 220 (8.7)

when crossbar is stored

B: ENGINE Model

2.5L SOHC non-turbo

Engine type Valve arrangement Bore × stroke Displacement

mm (in) cm3

Compression ratio Ignition order Idle speed at Park or Neutral position Maximum output Maximum torque

(cu in)

rpm

kW (HP)/rpm N·m (kgf-m, ft-lb)/rpm

3.6L DOHC non-turbo

Horizontally opposed, liquid cooled, Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine 6-cylinder, 4-stroke gasoline engine Overhead camshaft 99.5 × 79.0 (3.917 × 3.110) 92.0 × 91.0 (3.622 × 3.583) 2,457 (149.9) 10.0 1—3—2—4

3,630 (221.4) 10.5 1—6—3—2—5—4

650 (MT) 675 (CVT)

700

127 (170)/5,600 230 (23.5, 170)/4,000

191 (256)/6,000 334 (34.1, 247)/4,400

C: ELECTRICAL Model Ignition timing (at idling) BTDC Spark plug Type and manufacturer Generator Type and capacity (5HR) Battery CCA

2.5L SOHC non-turbo

3.6L DOHC non-turbo 15°

NGK: SIFR6A11 12 V — 110 A

NGK: SILFR6C11 12 V — 130 A 12 V — 52 AH (75D23R) 490 A

SPC-6

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OUTBACK SPECIFICATIONS

D: TRANSMISSION 1. MT Model Transmission type Clutch type

2.5L SOHC non-turbo 6MT DSPD 3.454 1.947 1.296 0.972 0.825 0.695 3.636

Gear ratio

1st 2nd 3rd 4th 5th 6th Rev.

Reduction gear (Front)

Type of gear Gear ratio

Hypoid 4.444

Transfer reduction

Type of gear Gear ratio

Helical 1.000

Final reduction

Type of gear Gear ratio

Hypoid 4.444

Reduction gear (Rear)

6MT: 6-forward and 1-reverse speeds with synchromesh for all gears DSPD: Dry Single Plate Diaphragm

2. AT Model Transmission type Clutch type 1st 2nd 3rd 4th 5th Rev.

Gear ratio

Reduction gear (Front)

3.6L DOHC non-turbo 5AT TCC 3.540 2.264 1.471 1.000 0.834 2.370

1st reduction

Type of gear Gear ratio

Helical 1.000

Final reduction

Type of gear Gear ratio

Hypoid 3.083

Type of gear Gear ratio

Hypoid 3.083

Reduction gear (Rear)

5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse TCC: Torque Converter Clutch

SPC-7

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OUTBACK SPECIFICATIONS

3. CVT Model Transmission type Clutch type Forward Rev.

Change gear ratio

Reduction gear (Front)

2.5L SOHC non-turbo CVT TCC 3.525 — 0.558 2.358

1st reduction Final reduction

Type of gear Gear ratio Type of gear

Helical 1.000 Hypoid

Gear ratio

3.900 1.000 Hypoid 3.900

Transfer reduction ratio Type of gear Gear ratio

Reduction gear (Rear)

TCC: Torque Converter Clutch CVT: Forward continuously variable speed change and 1-reverse

E: STEERING Model Type Turns, lock to lock Minimum turning diameter

2.5L SOHC

3.6L DOHC Rack & pinion 3.2

m (ft)

Curb to curb Wall to wall

11.0 (36.1) 11.8 (38.7)

F: SUSPENSION Front REAR

Macpherson strut type suspension Double wishbone type suspension

G: BRAKE Model Service brake system Front REAR Parking brake Brake assist

2.5L SOHC non-turbo 3.6L DOHC non-turbo Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Disc brake Ventilated disc brake Electric mechanical on rear brakes Standard equipment for all vehicles

H: TIRE Model Wheel size Tire size

2.5L SOHC non-turbo 16 × 6 1/2JJ 17 × 7J P215/70 R16 99S P225/60 R17 98T

Type

3.6L DOHC non-turbo 17 × 7J P225/60 R17 98T

Tubeless, Steel belted radial

SPC-8

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OUTBACK SPECIFICATIONS

I:

CAPACITY

Model

6MT

Fuel tank Total capacity (at overhaul) Engine Filling amount of oil engine oil 2 (US qt, Imp qt) Transmission gear oil

2 (US gal, Imp gal)

2.5L SOHC non-turbo CVT 70 (18.5, 15.4)

3.6L DOHC non-turbo 5AT

2 (US qt, Imp qt)

4.8 (5.1, 4.2)

4.8 (5.1, 4.2)

7.8 (8.2, 6.9)

When replacing engine oil and oil filter

4.2 (4.4, 3.7)

4.2 (4.4, 3.7)

6.5 (6.9, 5.7)

When replacing engine oil only 2 (US qt, Imp qt)

4.0 (4.2, 3.5) 3.7 (3.9, 3.3)

ATF or CVTF

2 (US qt, Imp qt)



Front differential gear oil Rear differential gear oil Power steering fluid Engine coolant

2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt)



6.5 (6.9, 5.7)

SPC-9

6.3 (6.7, 5.5) —

12.0 — 12.5 (12.7 — 13.2, 10.6 — 11.0)

9.8 (10.4, 8.6)

1.4 (1.5, 1.2) 0.8 (0.8, 0.7) 0.7 (0.7, 0.6) 6.4 (6.8, 5.6) 6.5 (6.9, 5.7)

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OUTBACK SPECIFICATIONS

SPC-10

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PRECAUTION

PC 1.

Page Precaution ..................................................................................................2

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Precaution PRECAUTION

1. Precaution

7. AIRBAG AND SEAT BELT PRETENSIONER DISPOSAL

A: CAUTION Please clearly understand and adhere to the following general precautions. They must be strictly followed to avoid minor or serious injury to the person doing the work or people in the area.

1. VEHICLE DYNAMICS CONTROL (VDC) Handle the VDC as a total system. Do not disassemble or attempt to repair individual parts. Doing so could prevent the VDC system from operating when needed, or the system may operate incorrectly and result in injury.

2. ELECTRONIC PARKING BRAKE Handle the electronic parking brake as a total system. Do not disassemble or attempt to repair individual parts. Doing so could prevent the electronic parking brake system from operating when needed, or the system may operate incorrectly and result in injury.

3. BRAKE FLUID If brake fluid gets in your eyes or on your skin, do the following: • Wash eyes and seek immediate medical attention. • Wash your skin with soap and then rinse thoroughly with water.

4. RADIATOR FAN The radiator fan may rotate without warning, even when the engine is not ON. Do not place your hand, cloth, tools or other items near the fan at any time.

5. ROAD TEST Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and interrupting traffic.

6. AIRBAG To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing maintenance on the airbag components and nearby, or around the vehicle front (radiator panel, front wheel apron, front side frame, front bumper, front hood panel, front fender panel), around side of the vehicle (front door panel, rear door panel, center pillar, rear fender panel, side sill, rear wheel apron) and the airbag wiring harnesses or nearby. To prevent unexpected deployment, turn the ignition switch to OFF and disconnect the ground cable from battery, then wait at least 60 seconds to discharge backup power supply before starting work.

To prevent bodily injury from unexpected airbag deployment, do not dispose the airbag modules or seat belt pretensioner in the same way as other waste. Follow the special instructions for disposal in this manual. Follow all government regulations concerning disposal of refuse.

8. AIRBAG MODULE Adhere to the following when handing and storing the airbag module to prevent bodily injury from unexpected deployment: • Do not hold the harnesses or connectors to carry the module. • Do not face the bag in the direction that it opens towards yourself or other people. • Do not face the bag in the direction that it opens towards the floor or walls.

9. AIRBAG SPECIAL TOOL To prevent unexpected deployment, only use special tools.

10.WINDOW Always wear safety glasses when working around any glass to prevent glass fragments from damaging your eyes.

11.WINDOW ADHESIVE Always use the recommended or equivalent adhesive when attaching glass to prevent it from coming falling, resulting in accidents and injury.

12.OIL When handling oil, carefully observe the following to prevent unexpected accidents. • Prepare a container and cloth to prevent scattering of oil when performing work where fuels can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government regulations concerning disposal of refuse when disposing.

13.FUEL When handling and storing fuel, carefully observe the following to prevent unexpected accidents. • Be careful of fires. • Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can be spilled. If the fuel spills, wipe it off immediately to prevent it from penetrating the floor or flowing out, to protect the environment. • Follow all government and local regulations concerning disposal of refuse when disposing.

PC-2

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Precaution PRECAUTION

14.ENGINE COOLANT When handling engine coolant, adhere to the following to prevent from unexpected accident. • Never remove the radiator cap since engine coolant may blow out when it is hot. • Prepare a container and cloth to prevent scattering of engine coolant when performing work where engine coolant can be spilled. If the oil spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing.

2. Removal and installation operation of hoses, etc. during the inspection • Follow the instructions below when removing hose. • Do not use a pointed hose remover (hose plucker) when using a general hose remover. It may damage the pipe surface or the hose.

15.AIR CONDITIONER REFRIGERANT In order to prevent from global warming, avoid releasing air conditioner refrigerant into the atmosphere. Using a refrigerant recovery system, discharge and reuse it.

16.REMOVAL AND INSTALLATION OPERATION OF HOSES, ETC. 1. Before the removal and installation operation of hoses, etc. • If you keep using the damaged or deformed hose, it results bleeds or leakage of the fat adheres or disconnection of the hose. Be careful not to spill fat adheres on exhaust pipes, etc. during maintenance to prevent emitting smoke or causing fires. • Perform the operation with the hose removed. If the operation is performed without removing the hose, it may damage inner surface of the hose.

NG N G OK K (1)

(1)

PC-00065

(1) Hose remover

• When draining hose using pliers, be sure to cover the hose with cloth and rotate the hose slightly to extract straight.

PC-3

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Precaution PRECAUTION

• If you keep using the hose, perform the inspection below and replace the hose with a new part if faulty. • Replace the hose with a new part if it rides over the stay or spool.

(2)

(1)

(1)

PC-00069

(1) PC-00071

(1) Hose rides over the stay

(1)

PC-00070

(1) Push against the spool. (Insert the hose and prevent it from becoming wrinkled.) (2) Tighten the hose outwards and apply force thoroughly.

PC-00068

(1) Hose rides over the spool

• Check if the surface and the inner surface of the hose are damaged, cracked, bend, hardened, softened, swelled, peeled or deformed due to the adherence or the entry of the foreign matter by bending the hose. Replace with the new part if faulty. • Follow the instructions below during installation. • Check carefully for assembling position. • Never use lubricants. • Insert the hose to the specified position (stopper or spool) securely.

• Check if the position, direction and hose layout of the hose clamp are correct. (Check if the position, direction, length and the gap around are correct, or if it is different from the condition before the work) • After the installation, check that the hose is installed securely and there is no leakage. (Check if it is fixed securely with the clamp) • For hose clips and hose clamps, perform the inspection below and replace them with a new part if faulty. • Check for deformation, rust, damage or foreign matters. • For hose clip, check if it works and has clamping force. • For hose clamp, check if it can tighten screw, not ovalized or the screw is not damaged. • For hose pipes, perform the inspection below and replace with a new part if faulty. Check if the pipe is not damaged, rusted, peeled (peeled plates included), covered with foreign matter, bent, compressed or cracked. • For the parts below, replaces with a new part when the hose is removed or the installation position is changed. ATF cooler hose, engine oil cooler hose, power steering suction hose, power steering return hose

PC-4

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NOTE

NT 1.

Page Note ............................................................................................................2

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Note NOTE

1. Note A: BASIC REPAIR HINT This section describes basic points that the service operator must understand before performing the service operation.

1. APPEARANCE • Always wear clean work clothing. • Wear a cap and protective shoes.

2. PROTECTION OF VEHICLE UNDER MAINTENANCE AND PREPARATION OF TOOLS/ EQUIPMENT • Before work, cover the vehicle body. (Ex. grille cover, fender cover, seat cover and floor mat cover) • Before performing the service operation, prepare tools, equipment, container box, grease and cloth etc.

(1) (2)

(3)

(4)

(5)

(6)

NT-00368

(1) (2)

Fender cover Tools/equipment case

(3) (4)

Tray Oil

(5) (6)

Container box Cloth

3. SAFETY

4. SERVICE OPERATION

• Before work, set the wheel stoppers to secure the vehicle. • When performing work by multiple workers, call to each other to make sure that service operation is performed safely. • Before starting engine, ventilate the room. • When performing the service operation of hightemperature parts like muffler, rotating parts like fan and other movable parts, be careful not to get burned or injured. • For the jack-up and lift up, set the tool to the proper location to support the vehicle correctly. And use the safety device properly when lifting up.

• By identifying the vehicle problems thoroughly before work, service operation will be performed effectively. • Before removing parts, confirm the installation condition or the damage of the parts. • To reinstall parts properly, leave a note of the condition before work as necessary. • For a part which needs positioning, take appropriate action such as putting alignment marks. • For a removed part, clean it as necessary and check for damage and defect before installation.

NT-2

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Note NOTE

5. REMOVED PART

4. BACKUP/POWER SUPPLY FUSE

• A removed part must be organized to avoid mixing up with similar parts. When same parts are used in multiple locations, such as pistons in engine, manage the parts by using labels with cylinder No. so that the parts are not installed to the wrong location. • Always replace nonreusable parts such as gasket and O-ring with new parts. • After work, have a customer confirm the replaced part.

Right after the vehicle has arrived, 10 A backup fuse is removed to avoid run-down of the battery. Connect the backup fuse as shown in the figure. Also, delivery mode is canceled by disconnecting the backup fuse from the fuse holder.

6. WHEN REMOVING BATTERY When removing battery, power supply is cut off and the information stored in the computer memory is volatilized. Therefore, setting information of some device is initialized to the factory default. The device and functions initialized by removing battery are as follows. • Clock • Set temperature of fully automatic air conditioner • Automatic full open/close of driver’s window (power window needs to be initialized) • User setting items in the navigation system • Past trouble history (memory code)

(1)

(3)

B: NOTE

(2)

This is the information that can improve the efficiency of maintenance and assure the sound work.

NT-00369

(1) Backup fuse insertion slot (2) Backup fuse holder (3) Backup fuse

1. FASTENERS NOTICE Tighten the bolts and nuts to the specified torque. Do not apply paint, lubricant, rust retardant or other substance to the surface around bolts, nuts, etc. It may cause troubles with tightening to the specified torque and result in looseness and other problems of bolts and nuts.

2. STATIC ELECTRICITY DAMAGE Touch grounded metal or equivalent for the elimination of static electricity before conducting work.

3. BATTERY When removing the battery terminal, always be sure to turn the ignition switch to OFF and remove the battery ground cable first.

5. IMMOBILIZER RELATED PART Do not replace parts which have immobilizer ID (ignition key, combination meter, body integrated unit and ECM) with the parts from other vehicle.

6. SERVICE PARTS Use genuine parts for maximum performance and maintenance when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts except for genuine parts.

7. PROTECTING VEHICLE UNDER MAINTENANCE Make sure to attach the fender cover, seat covers, etc. before work.

8. ENSURING SECURITY DURING WORK When working in a group of two or more, perform the work with calling each other to ensure mutual safety.

NT-3

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Note NOTE

9. LIFT AND JACK When using a lift or shop jack to raise a vehicle or using rigid rack to support a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful that the vehicle is balanced before raising it. Be sure to set the wheel stoppers when jacking-up only the front or rear side of the vehicle. CAUTION: Select the lift attachment so that the side sill does not contact the lift arm portion. NOTE: • When using a lift, follow its operation manual before work. • If side sill cover touches the lift arm, use lift attachment. • Do not work or leave unattended while the vehicle is supported with jack, support it with rigid racks. • Be sure to use the rigid racks with rubber attached to cradle to support the vehicle. • When using a plate lift, use a rubber attachment. Place the attachment to the specified position of the vehicle, by adjusting front/rear and left/right sides accordingly.

(A) (C) (B) NT-00070

(A) 80 mm (3.1 in) or more (B) 100 — 150 mm (3.94 — 5.91 in) (C) 120 — 190 mm (4.72 — 7.48 in)

• Align the cushion rubber center of plate lift with the center of rubber attachment. • Do not use the plate lift whose attachment does not reach the supporting locations.

NT-4

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Note NOTE

• SUPPORT LOCATIONS

(1)

(1) NT-00360

(1)

Jack-up point

• PANTOGRAPH JACK

(1)

(1)

NT-00383

(1)

Jack-up point

NT-5

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Note NOTE

• Lift

NT-00271

CAUTION: For models with side under skirt, use a spacer or an attachment to lift up the vehicle securely at jack up point, without contact of side under skirt and lift. • RIGID RACK

NT-00384

NT-6

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Note NOTE

• PLATE LIFT

(1)

(1)

(2)

NT-00370

(1)

Jack-up point

(2)

Attachment

• Jack-up point (when using garage jack)

(A)

(1)

(B) (2)

NT-00382

(A) (1)

Front Front cradle

(B) (2)

Rear Rear differential

CAUTION: If jacking up the front side of the vehicle, make sure that the jack is attached at the center of the jackup plate not at the sides.

NT-7

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Note NOTE

10.TIE-DOWNS Tie-downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-down only to the specified locations on the vehicle. • TIE-DOWN LOCATION

(2) (1)

NT-00381

(1)

Hook for tie-down

(2)

Tie-down hole

NT-8

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Note NOTE

• CHAIN DIRECTION AT TIE-DOWN CONDITION CAUTION: • Pull the tie-down chains LH and RH in the same direction, but front and rear side in the counter direction. • Patterns except for the followings (recommended) are not allowed.

NT-00372

NT-9

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Note NOTE

• TIE-DOWN RANGE For ground transportation CAUTION: When the vehicle is tied down from vehicle inside, hook the hooks of tie-down chain on the rear tiedown hooks from vehicle inside. When the vehicle is tied down from vehicle outside, hook the hooks of tie-down chain on the rear tie-down hooks from vehicle outside.

20

20

20

20 20

20

20

20 20

20

20

20

20

20

(B) (A)

45

45

45

45

:(C) NT-00385

(A)

Front tie-down hook

(B)

Rear tie-down hole

NT-10

(C)

Chain pulling range at tie-down condition

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Note NOTE

(D)

45

For sea transportation 45

(1

38

1.

8)

(E) 45 70

45

45

(A)

(B)

45

45

(F) :(C) NT-00386

(A)

Front tie-down hook

(C)

(B)

Tie-down hole or wheel spoke

(D)

Chain pulling range at tie-down condition 400 mm (15.7 in)

(E)

1,320 mm (52.0 in)

(F)

When rear wheel is tied down

CAUTION: • Basically, tie down using the tie-down hole. • Tie-down procedure should be followed as much as reasonably possible depending on the deck condition, however, lashing belt and vehicle must not contact each other. Also, if a wheel tie-down is conducted instead of using rear tie-down hole due to the vehicle loading condition of the deck, follow the instructions below. 1. Tie-down range must be within the backward of rear wheel as shown in the figure. 2. Wheel tie-down should be used only during sea transportation, and lashing belt should not contact air valve while tie-down. Be careful not damage the wheel and vehicle. 3. Maximum tie-down load to each lashing belt is 5000 N (510 kgf, 1124 lbf). 4. For steel wheel, do not tie down wheels.

NT-11

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Note NOTE

• VEHICLE SINKING VOLUME AT TIE-DOWN CONDITION CAUTION: The vehicle sinking volume at tie-down condition should be less than 50 mm (1.97 in) and make sure to fix the vehicle securely. Check to see if the tensions of chains or belts at tie-down condition are appropriate in the following procedures. 1) Measure the distance (A) between the center of wheel and highest arch point. 2) Compare the above dimensions of before and after tie-down. 3) If the distance is less than 50 mm (1.97 in), it is judged as OK. If the distance is 50 mm (1.97 in) or more, it is judged as NG because the tension is too high.

(B) (A)

(C)

NT-00387

(B)

Arch position before tie-down

(C)

Arch position after tie-down

• NOTES FOR THE USE OF TIE-DOWN HOOK When the vehicle is tied down from vehicle inside, hook the hooks of tie-down chain from vehicle inside, and when the vehicle is tied down from vehicle outside, hook the hooks of tie-down chain from vehicle outside. For front tie-down hook, use S hook and J hook, and for rear tie-down hole, use S hook, J hook and T hook. T hook can be used only for rear tie-down hole.

NT-12

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Note NOTE

11.TOWING Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD, AT or VTD, use a loader instead of towing. When towing other vehicles, pay attention to the following to prevent hook or vehicle damage resulting from excessive weight. • Do not tow other vehicles with a front tie-down hook. • Make sure the vehicle towing is heavier than the vehicle being towed. • Front Remove the hook cover, and install the hook.

(A)

(B)

NT-00378

(A)

Hook cover

(B)

Hook

• Rear Remove the hook cover, and install the hook.

(A)

(B)

NT-00377

(A)

Hook cover

(B)

Hook

NT-13

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Note NOTE

• Precautions Towing Lifting up four wheels (On a trailer)

Precautions Towing the vehicle after lifting up all four wheels is a basic rule for AWD model.

NT-00023

Rope

• Check if both front and rear wheels are rotated normally. • AT model driving conditions: Driving speed of 30 km/h (19 MPH) or less Allow driving distance 50 km (31 miles) or less

NT-00024

Raising the front wheels

Prohibited for full-time AWD model.

NT-00025

Lifting up the front wheels

• Prohibited, due to damage on bumper, front grille, etc. • Do not raise the vehicle with bumper.

NT-00026

Marked

: OK, Marked

: Prohibited, Marked

: Conditionally OK.

NT-14

MT

AT

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Note NOTE

CAUTION: • Place the shift lever in “N” position during towing. • Do not lift up the rear wheels to avoid unsteady rotation. • Turn the ignition key to “ACC”, then check the steering wheel moves freely. • Release the parking brake to avoid tire dragging. • Since the power steering does not work, be careful for the heavy steering effort. (When engine is stopped) • Since the servo brake does not work, be careful that the brake is not applied effectively. (When engine is stopped) • In case of the malfunction of internal transmission or drive system, lift up four wheels (on a trailer) for towing. • Do not use towing hook except when towing. • Make sure to detach the towing hook after towing. If the hook remains attached, airbag may not operate properly when receiving a shock from front side.

12.FRONT HOOD DAMPER STAY 1) When performing inspection or general maintenance, install the damper stay to the normal position. CAUTION: When performing inspection or general maintenance, do not remove the damper stay.

(1)

NT-00366

(1)

Normal installation position

NT-15

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Note NOTE

2) When front hood needs to open wider, set the damper stay into the hole of lower hood as shown in the figure below.

Tightening torque:

CAUTION: • Always perform inspection and general maintenance works with both damper stays attached. • Do not keep detaching the damper stay on one side. • The hood cannot be closed with the hood dumper at the full open position. When closing the hood, tie the hood striker and radiator panel and secure them. • After work, make sure to return the damper stay to normal installation position and tighten the bolt to the specified torque.

(1) (2)

NT-00367

(1)

Normal installation position

(2)

Installation position at full open

NT-16

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Note NOTE

13.GENERAL SCAN TOOL Using general scan tools will greatly improve the efficiency of repairing engine electronic throttle controls. Subaru Select Monitor can be used to diagnose the engine, VDC, air conditioner and other parts.

14.AWD CIRCUIT MEASURES 1) Full-time AWD MT model Since viscous coupling (limited slip differential) is used in the center differential, cut-off of AWD circuit cannot be carried out. 2) Full-time AWD 5AT model Since VTD type is used in the center differential, cut-off of AWD circuit cannot be carried out. 3) Full-time AWD CVT model Since electronically controlled MT-P hydraulic multi-plate clutch is adapted for center differential, switch to FWD by using Subaru Select Monitor.

2) Rear wheel jack-up system (1) Set the vehicle on speedometer tester. CAUTION: Fix the vehicle using a pulling metal (chain or wire) to the front and rear towing hooks or tiedown hook to prevent the lateral runout of front wheels and springing out of vehicle. (2) Jack up the rear wheels and set the rigid racks to the specified locations of side sill.

(A)

NT-00034

15.SPEEDOMETER TEST 1) Rear wheel free roller system (1) Set the free roller on the floor of rear wheel side securely according to the wheel base and rear tread of the vehicle. (2) Let the vehicle ride on the tester and free roller gently. CAUTION: Fix the vehicle using a pulling metal (chain or wire) to the front and rear towing hooks or tiedown hook to prevent the lateral runout of front wheels and springing out of vehicle.

(A) RIGID RACK

(3) Conduct the speedometer test work. CAUTION: Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work.

16.BRAKE TEST 1) Full-time AWD MT model (1) Perform this test after driving the vehicle 2 to 3 km (1.24 to 1.86 miles) on road in order to stabilize the viscous torque of viscous coupling. (2) Keep the front or rear wheels on the ground for this test. NOTE: Effect of the viscous torque on braking force will be added approx. 25 kg compared with FWD model.

(A) NT-00033

(A) Free roller

(3) Set the speedometer tester. (4) Conduct the speedometer test work.

(C)

CAUTION: Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work.

NT-17

(A)

(B) NT-00029

(A) Brake tester (B) Position for measuring front wheel (C) Position for measuring rear wheel

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Note NOTE

(3) When the brake dragging force is large. • Check the dragging of brake pad or brake shoe. • Since it may be affected by the viscosity of viscous coupling, jack up either of the front or rear two wheels to check the each wheel rotation condition with the viscous coupling affection removed. 2) Full-time AWD AT model (1) Keep the front or rear wheels on the ground during measurement.

(C)

(A)

17.ON THE CAR WHEEL BALANCING CAUTION: • Carry out the procedures after measuring the balance of each single tire. • Set the vehicle so that the front and rear wheels are the same height. • Release the parking brake during measurement. • Rotate each wheel by hands, and make sure it rotates without dragging. • Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work. • When an error is indicated during engine drive, do not use the motor drive together. 1) Set the rigid rack to the specified locations of side sill, jack up the front or rear two wheels of nonmeasuring side and set the pickup stands to two wheels of measuring side.

(B) NT-00029

(A)

(A) Brake tester (B) Position for measuring front wheel (C) Position for measuring rear wheel

(2) When the brake dragging force is large. • Check the dragging of brake pad or brake shoe.

(B)

Specifications: Rear wheel total Difference between right and left wheels Grand total

NT-00374

(A) Balancer body (B) Pickup stand (left and right)

Braking force 10% or more of load on front or rear wheels 8% or less of load on front or rear wheels 50% or more of vehicle weight at the time of test

2) For drive wheel, drive the tires with engine for measurement. 3) For non-drive wheel, drive the tires from the on the car wheel balancer for measurement.

• When measurement is difficult to carry out because both of front wheels are locked, break force measurement in this condition conforms to standard grand total.

NT-18

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IDENTIFICATION

ID 1.

Page Identification ...............................................................................................2

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Identification IDENTIFICATION

1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER & LABEL LOCATIONS The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle. • POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION

(4) (5)

(3)

(1)

(2)

ID-00320

(1) (2)

Vehicle identification number (V.I.N.) FMVSS label (U.S. model) (left side) CMVSS label (Canada model) (left side) Model No. label (Korea model) (right side)

(3)

VIN cover (turbo model)

(4)

Intercooler (turbo model)

ID-2

(5)

VIN plate

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Identification IDENTIFICATION

• ENGINE

• MANUAL TRANSMISSION 6MT (1)

(1) (2) ID-00059 ID-00318

(1) Engine serial number (punch mark) (2) Engine type (casting) crankcase upper side

(1) Transmission serial number and MT type label

• REAR DIFFERENTIAL T-type

• AUTOMATIC TRANSMISSION 5AT

(1)

(1)

ID-00257

ID-00314

(1) Type (white paint)

(1) Transmission serial number and AT type label

VA1-type

CVT (2)

(1)

(3)

(1) ID-00312 ID-00316

(1) Type (label)

(1) Label (2) CVT type label (3) Transmission serial No. label

VA2-type

(1)

DI-00607

(1) Type (label)

ID-3

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Identification IDENTIFICATION

• FMVSS LABEL, CMVSS LABEL Example

ID-00321

• MODEL NUMBER LABEL

ID-00322

ID-4

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Identification IDENTIFICATION

2. MEANING OF V.I.N. The meaning of the V.I.N. is as follows: ]4S3BMAA6XA1210001[ The starting and ending brackets ( ] [ ) are stop marks. Digits 1—3

4S3

Code

Meaning Manufacturer of body area Car line Body type

4 5

B M

6

A

Total emission and destination

7

A

Grade

8

6

Restraint system or GVWR Class

9 10 11

X A 1

Check digit Model year Transmission type

12 — 17

210001

Serial number

Details 4S3: All models except OUTBACK model for C0 4S4: OUTBACK for C0 B: LEGACY/OUTBACK M: Sedan R: Wagon A: 2.5L non-turbo for U4 B: 2.5L non-turbo for U5 C: 2.5L non-turbo for U6 D: 3.6L non-turbo for U5 E: 3.6L non-turbo for U6 F: 2.5L turbo for U4 G: 2.5L non-turbo for C0 H: 2.5L non-turbo for C5 J: 3.6L non-turbo for C0 K: 2.5L turbo for C0 L: 2.5L non-turbo for C6 M: 3.6L non-turbo for C6 A: Base B: Premium C: Premium + cold weather package D: Premium + 6CD harman/kardon E: Premium + M/R F: Premium + 6CD harman/kardon + cold weather package G: Premium + M/R + cold weather package H: Premium + M/R + cold weather package + 6CD harman/kardon J: Limited + 6CD harman/kardon K: Limited + 6CD harman/kardon + M/R L: Limited + M/R + navigation M: Limited + M/R 6: Manual belt, dual airbag, side airbag for seat back + curtain airbag for roof (except for OUTBACK model) C: Manual belt, dual airbag, side airbag for seat back + curtain airbag for roof, class C (GVWR 4001 — 5000 lb) (for OUTBACK model) 0 — 9&X A: 2010MY 1: Full-time AWD 6MT 2: Full-time AWD 5AT 3: Full-time AWD CVT 210001 — : Sedan 310001 — : Wagon

ID-5

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Identification IDENTIFICATION

3. MODEL NUMBER PLATE The model number plate indicates applied model, option code, trim code, engine type, transmission type and the exterior color code. This information is helpful when placing orders for parts. • BM9AY4M Digits

Code

1 2

B M

3

9

4 5 6

A Y 4

7

M

Meaning Series Body type

Details LEGACY M: Sedan R: Wagon

Total engine displacement Drive system Suspension system Model year Destination Grade

Transmission, fuel feed system

9: 2.5L AWD F: 3.6L AWD

A: 2010MY Y: US, Canada 4 : 2.5i 5: 2.5i Premium 6: 2.5i Limited C: 2.5GT Premium D: 2.5GT Limited F: 3.6R H: 3.6R Limited K: OUTBACK 2.5i L: OUTBACK 2.5i Premium M: OUTBACK 2.5i Limited S: OUTBACK 3.6R U: OUTBACK 3.6R Limited 9: SOHC MFI CVT M: SOHC MFI 6MT U: DOHC MFI 5AT X: DOHC MFI turbo 6MT

The engine and transmission type are as follows. • ENGINE EJ253CDAFB Digits 1 and 2

EJ

Code

Meaning Engine type

3 and 4

25

Displacement

5

3

Fuel feed system

6

C

Emission regulations

7

D

Mounted transmission

8 — 10

AFB

Detailed specifications

Details EJ: 4 cylinders EZ: 6 cylinders 25: 2.5L 36: 3.6L 3: MFI non-turbo (SOHC) 5: MFI turbo D: MFI non-turbo (DOHC, H6) A: For states not using California emission standards B: For USA C: For states using California emission standards C: D5AT D: 6MT (T75) U: CVT Used when ordering parts. For details, refer to the parts catalog.

ID-6

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Identification IDENTIFICATION

• TRANSMISSION 1. MT TY756WCAAA Digits 1 2 3 and 4 5 6

T Y 75 6 W

Code

7

C

Meaning Transmission Transmission type Identification Series Transmission specifications Equipped vehicle

8 — 10

AAA

Detailed specifications

Details T: Transmission Y: Full-time AWD MT center differential 75: 6MT 6: 6MT W: Full-time AWD 6MT single range with viscous coupling center differential C: 2.5L SOHC non-turbo L: 2.5L DOHC turbo Used when ordering parts. For details, refer to the parts catalog.

2. AT TG5D8CJAAA Digits 1 2 3 and 4 5 6

T G 5D 8 C

Code

7 8 — 10

J AAA

Meaning Transmission Transmission type Identification Series Transmission specifications Equipped vehicle Detailed specifications

Details T: Transmission G: Full-time AWD 5AT center differential 5D: 5AT 8: 5AT C: Full-time AWD VTD 5AT J: 3.6L DOHC non-turbo Used when ordering parts. For details, refer to the parts catalog.

3. CVT TR690JHAAA Digits

Code

1 2 3 and 4

T R 69

5 6

0 J

7 8 — 10

H AAA

Meaning Transmission Transmission type Distance between gear center Series Transmission specifications Mounted engine Detailed specifications

Details T: Transmission R: Full-time AWD CVT 69: CVT 0: CVT J: Active torque split type full-time AWD CVT H: 2.5L SOHC non-turbo Used when ordering parts. For details, refer to the parts catalog.

ID-7

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Identification IDENTIFICATION

• Rear differential Code B1 B2 XC XD T2 TP

Reduction gear ratio 4.111 3.900 3.083 3.700 4.111 4.444

LSD No No No No No No

• OPTION U5DC Digits 1—2

U5

Code

Meaning Destination

3

D

Option equipment

4

C

Option equipment

Details C0: Canada C5: Canada (PZEV) C6: Korea U4: USA U5: USA (for states using California emission standards) U6: USA (for states not using California emission standards) A: Cruise control B: A package, power seat, cruise control C: A package, power seat, genuine leather seat, cruise control D: A package, cruise control 6: Special edition A: Winter pack, side & curtain airbag B: Side & curtain airbag C: Winter pack, side & curtain airbag, sunroof D: Side & curtain airbag, sunroof E: Winter pack, navigation + wide monitor, side & curtain airbag, sunroof F: Dark colored glass, winter pack, side & curtain airbag, sunroof F: Dark colored glass, side & curtain airbag, sunroof H: Dark colored glass, winter pack, navigation + wide monitor, side & curtain airbag, sunroof I: Dark colored glass, winter pack, side & curtain airbag J: Dark colored glass, side & curtain airbag V: harman/kardon audio, side & curtain airbag, sunroof, winter pack V: harman/kardon audio, side & curtain airbag, winter pack Y: Dark colored glass, winter pack, harman/kardon audio, side & curtain airbag, sunroof Z: Dark colored glass, winter pack, harman/kardon audio, side & curtain airbag 1: Special edition 2: Special edition

ID-8

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RECOMMENDED MATERIALS

RM 1.

Page Recommended Materials ...........................................................................2

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Recommended Materials RECOMMENDED MATERIALS

1. Recommended Materials A: RECOMMENDED MATERIALS 1. GENERAL To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or a substitute of equivalent quality.

2. FUEL • Use unleaded gasoline to reduce air pollution, because using leaded gasoline will damage the catalytic converter. • Do not use the low quality gasoline, or improper fuel such as diesel fuel, fuel alcohol, or gasoline additive because they will adversely affect on engine components. • Always use gasoline that is equivalent to that prescribed in the owner’s manual or that of high octane value. There is the possibility of damaging or improper operation of the engine and fuel injection system if the specifications are not observed. Use the prescribed gasoline type to maintain proper vehicle performance.

3. LUBRICANTS Use the lubricants shown in the table below, or equivalent. See the table below to choose the correct SAE viscosity. LUBRICANT

ILSAC standard

SM grade “Energy conserving”

GF-4

SERVICE S PI

N AM ER I CA

NG

VI R

C

ER

T I F IE

RM-00049

Manual Transmission Oil Front differential gear oil Rear differential gear oil

GL-5 GL-5 GL-5

RM-2

TUTE

CONS E

FOR GASOLINE ENGINES

ST I

E

GY

TR OLEUM

IN

EN

SAE 5W-30 R

PE

M

A

Engine oil Choose oil suitable for the standard from the right.

Recommended materials API standard

D RM-00002

— — —

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Recommended Materials RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Engine oil

(˚C)

–30

–20

–10

0

10

20

30

40

(˚F)

–22

–4

14

32

50

68

86

104

10W-30 or 10W-40

5W-30 Recommend

RM-00059

Manual transmission oil, rear differential gear oil, AT and CVT front differential gear oil (˚C)

–30

–20

–10

0

10

20

30

40

(˚F)

–22

–4

14

32

50

68

86

104

90

85W

80W

75W-90 RM-00004

RM-3

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Recommended Materials RECOMMENDED MATERIALS

4. FLUID Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid. CAUTION: Be sure to use the recommended or equivalent ATF. Using material except recommended one or substitute would cause trouble. Fluid Automatic transmission fluid

Recommended materials CVT 5AT

Power steering fluid Brake fluid Clutch fluid

Item number

Alternative

K0425Y0710



— K0515YA000

IDEMITSU: ATF HP DEXRON III









Recommended materials SUBARU SUPER COOLANT

Item number K0670Y0001

Alternative —

Cooling system conditioner

SOA345001



SUBARU CVT OIL FOR LINEARTRONIC SUBARU ATF HP SUBARU PS fluid FMVSS No. 116 DOT3 or DOT4 FMVSS No. 116 DOT3

5. COOLANT Use genuine coolant to protect the engine. Engine coolant Coolant Cooling system protective agent

6. REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any compressor oil other than DENSO OIL 8. Air Conditioner Refrigerant Compressor oil

Recommended materials HFC134a DENSO OIL 8

RM-4

Item number — —

Alternative — —

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Recommended Materials RECOMMENDED MATERIALS

7. GREASE Use grease and supplementary lubricants shown in the table below. Grease Supplementary lubricants Grease

Application point Oxygen sensor • MT main shaft (spline parts) • MT main shaft (oil seal lip) • Clutch release lever Clutch master cylinder push rod • Gear shift lever • Clutch operating cylinder • Clutch pedal • Brake pedal • Release bearing • Select lever (Except for shift lock parts) Select lever (Shift lock parts) • Door latch • Door striker Steering gearbox Disc brake (lock pin, guide pin, piston boot) Between brake pad and shim Brake pad clip Front axle AAR • Rear axle BJ • Rear axle EBJ Rear axle DOJ

Recommended materials

Item number

Alternative

Spray type lubricant





NICHIMOLY N-130





SILICONE GREASE G-40M





NIGTIGHT LYW No. 2 grease





Multemp D





SILICONE GREASE G-30M

004404002



VALIANT GREASE M2

003608001

ONE LUBER SG or MO

K0779GA102



K0777YA010







One-Luber GKN-C





NKG106





NKG205





Item number

Alternative





65029FC000



Brake grease (NIGLUBE RX-2) Molykote AS-880N Molykote M7439 (Brake Grease 60G)

8. ADHESIVE Use the adhesives shown in the table below, or equivalent. Adhesive Adhesive

Application point Windshield, rear window glass, rear quarter glass, rear gate glass and body Rearview mirror base

Recommended materials Dow Automotive’s adhesive: ESSEX U-400HV or the equivalent Glass primer: U-401 and U-402 Paint surface primer: U-413 REPAIR KIT IN MR

RM-5

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Recommended Materials RECOMMENDED MATERIALS

9. SEAL MATERIAL Use the seal material shown in the table below, or equivalent. Seal material

Recommended materials

Item number

Alternative

THREE BOND 1215

004403007

DOW CORNING No. 7038

Transmission oil pan (AT and CVT model)

THREE BOND 1217B

K0877YA020



• Cylinder block • Camshaft cap • Oil pump (Except for 3.6 L model) • Rocker cover (3.6 L model or turbo model) • Oil pan (block lower) (except 3.6 L model) • Oil pan (oil pan upper) (3.6 L model) • Block lower (block) (except 3.6 L model) • Block (oil pan upper) (3.6 L model) • Back chain cover (front chain cover, block, head, oil pan upper) (3.6 L model) • Separator cover (except for 3.6 L model) • Scavenge pump (turbo model)

THREE BOND 1217G

K0877Y0100



THREE BOND 1324

004403042



THREE BOND 1105

004403010

DOW CORNING No. 7038

SEAL END No. 22 THREE BOND 1141G

— —

— —

3M Butyl Rubber 8626





THREE BOND 1110B

K0879Y0020



• • • • • • •

Seal material

Application point MT transmission case Converter case CVT converter case CVT transmission case CVT intermediate case CVT converter cover CVT chain cover

• Engine oil pressure switch • Rear differential lock nut (companion flange) • Rear differential driven gear mounting bolt threaded portion • Engine oil separator cover threaded portion (when reusing bolts) • Engine oil pump mounting bolt threaded portion (when reusing the bolt) (when reusing bolts) • Timing belt guide cam sprocket side mounting bolt threaded portion (when reusing the bolt) (when reusing bolts) • Rear differential • PCV valve (except 3.6L model) • Service hole plug • Intake manifold nipple Seal material

Steering adjusting screw PCV valve (3.6L model) • Front sealing cover (door) • Rear sealing cover (door) Rear differential (side retainer bolt)

RM-6

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PRE-DELIVERY INSPECTION

PI 1.

Page Pre-delivery Inspection ...............................................................................2

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

1. Pre-delivery Inspection A: GENERAL DESCRIPTION The purposes of the pre-delivery inspection (PDI) are as follows. • Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal condition. • Check the vehicle before delivery is in normal condition. • Check the vehicle has no damage and no vehicle protective parts are missing while shipped or stored in a car barn. • Make sure to deliver a complete vehicle to customer. For above reasons, all SOA service center must carry out the PDIs before delivery of vehicle. Besides, all SOA service center and PDI center check the condition of all vehicles to make sure to take responsibility.

B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE Static Checks Just After Vehicle Receipt Procedure 1. Appearance

2. Tire 3. Fuse 4. Lock/unlock and open/close operation of doors.

5. Child safety lock system 6. Trunk lid open/close

7. Trunk lid release lever 8. Lock/unlock and open/close operations of rear gate

9. Fuel lid opener lever 10. Accessories

Check point 1. If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. If the protective coating has been removed, visually inspect the body paints for small areas of damage or rust. 2. Visually check the glass and light lenses for any damage, cracks or excessive gaps between body sheet metal. 3. Visually check the plated parts for any damage. 4. Check the instrument panel, console, and trims for stains or dirt. 1. Check the tires for damage, defective, and dents on wheels. 2. Check the tire air pressure. If the vehicle is about to be delivered to customer, attach a back-up fuse. 1. Using the key, check the door can be locked or unlocked normally. 2. Open and close all doors to check that there are no defective. 3. Operate the power door lock switch to check that all doors and the rear gate lock and unlock normally. Check the child safety lock system operates normally. 1. Press the trunk opener switch for approx. one second to check for normal operation of the trunk lid. 2. Check that main and sub keys can lock/unlock the release lever, and that valet key can not lock/unlock the release lever. 3. Open and close the trunk lid to see that there are no abnormal conditions. Operate the trunk lid release lever to check that the trunk lock is unlocked normally. 1. Open and close the rear gate to see that there are no problems. 2. Check if the rear gate can be unlocked normally through the emergency hole. 3. Operate the power door lock switch to check that all doors and the rear gate lock and unlock normally. Operate the fuel lid opener to check that the fuel lid is unlocked normally. Check that the following accessories are provided. • Owner’s manual • Warranty booklet • Maintenance note • Spare key • Key number plate • Jack • Tool set • Spare tire • Towing hook (Eye bolt) • Security ID plate

PI-2

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Pre-delivery Inspection PRE-DELIVERY INSPECTION Procedure 11. Front hood lock release system 12. Battery 13. Brake fluid 14. Engine oil 15. Transmission gear oil 16. CVT front differential gear oil 17. Engine coolant 18. Clutch fluid 19. Window washer fluid 20. Front hood latch 21. Keyless entry system 22. Security system (Alarm system) 23. Seat

24. Seat belt 25: TPMS (U.S. models)

Check point Operate the front hood lock release lever to check that the front hood opens normally. Check the battery for any abnormal conditions such as rust and trace of battery fluid leaks. Check the brake fluid amount. Check the engine oil amount. Check that the transmission gear oil level is normal. Check for no leakage of CVT front differential gear oil. Check the engine coolant amount. Check the clutch fluid amount. Check the window washer fluid amount. Check that the front hood is closed and locked normally. Check that the keyless entry system operates normally. Check that the security system (alarm system) operates normally. 1. Check the seat surfaces for stains or dirt. 2. Check the seat installation conditions and functionality. 3. Check that the occupant detection system for passenger’s seat operates normally. 1. Check the seat belt installation conditions and functionality. 2. Check the seat belt warning system operates normally. 1. Turn the transmitter power of TPMS to ON. 2. When the display of the TPMS warning light does not operate normally, perform the diagnosis while referring to TPMS(diag).

Checks with the Engine Running Procedure 26. Immobilizer system

27. Starting condition 28. Exhaust system 29. Indicator and warning lights 30. Heater & ventilation 31. Air conditioner 32. Clock 33. Audio 34. Navigation system

35. Accessory power supply socket 36. Lighting system 37. Wiper deicer 38. Illumination control 39. Window washer 40. Wiper 41. Power window 42. Sunroof 43. Door Mirror 44. Parking brake

Check point 1. Check that the engine starts with all keys that are equipped on vehicle. 2. 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing the key, check that the security indicator light is blinking. Start the engine and check that the engine starts smoothly. Check that the exhaust noise is normal and no leaks are found. Check that all indicator lights and warning lights operate normally. Check that the heater & ventilation system operates normally. Check that the air conditioner operates normally. 1. Check that the clock operates normally. 2. Check for normal switch operation of fuel economy display. 1. Check that the audio system operates normally. 2. Check that the radio, CD and AUX systems operate normally. 1. Check all display functions for normal operation. 2. Check that the navigation, audio and AUX systems operate normally. 3. Check that the rearview camera operates normally. Check that the accessory power supply socket operates normally. Check that the lighting system operates normally. Check that the wiper deicer operates normally. Check that the illumination control operates normally. Check that the window washer system operates normally. Check that the wiper system operates normally. Check that the power window operates normally. Check that the sunroof operates normally. Check that the remote control mirror operates normally. Check the parking brake for normal operations.

PI-3

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

Dynamic Test with the Vehicle Running Procedure 45. Brake test 46. AT shift control 47. MT shift control 48. Cruise control

Check point Check the foot brake for normal operations. Check that the AT shifts normally. Check that the MT shifts normally. Check that the cruise control system operates normally.

Checks after Dynamic Test Procedure 49. ATF level 50. CVTF 51. AT front differential oil 52. Power steering fluid level 53. Fluid leakage 54. Water leakage 55. Appearance 2

Check point Check that the ATF level is correct. Check for leakage of CVTF. Check for leakage of AT front differential oil. Check that the power steering fluid level is normal. Check for fluid/oil leaks. Spray the vehicle with water and check for water leaks. 1. Remove the protective coat. (If attached) 2. Check the body paints for damage and stain. 3. Check the plated parts for damage and rust.

1. APPEARANCE

3. FUSE

• If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. • When the protective coating is removed, visually check the body paints for damage or stains in detail and repair as necessary. • Visually check the windshield glass, door glasses and light lenses for any damage, cracks or excessive gaps to the body sheet metal and repair as necessary. • Visually check the plated parts, such as the grilles and door knobs, for damage or loss of gloss and replace the parts as necessary. • Check the instrument panel, console, and trims for stains or dirt.

Right after the vehicle has arrived, 10 A backup fuse is removed to avoid run-down of the battery. Connect the backup fuse as shown in the figure. Also, delivery mode is canceled by disconnecting the backup fuse from the fuse holder.

2. TIRE • Check the tires for damage, defective, and dents on wheels. • Check and correct the tire size, spare tire and tire air pressure described on the tire air pressure label (driver’s side).

(1)

(3)

(2) NT-00369

(1) Backup fuse insertion slot (2) Backup fuse holder (3) Backup fuse

PI-4

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

4. LOCK/UNLOCK AND OPEN/CLOSE OPERATION CHECKS OF DOORS.

4) Press the driver’s side power door lock switch to unlock side. Check that all doors including rear gate are unlocked.

1) Using the key, lock and unlock the door several times to check for normal operation. Open and close the door several times for smooth movement.

PI-00614

5) Check that the passenger’s side power door lock switch locks and unlocks normally in the same manner.

PI-00604

2) Completely close the driver’s door, and then check the smooth movement with operating door lock knob from lock to unlock several times. Set the door lock knob (A) to lock position. Then pull the inner remote (B) to ensure that doors will not open. For other doors, place the door lock knob (A) to lock position and then pull the inner remote (B) to ensure that doors will not open.

(A) (B)

(A)

PI-00615

(A) Lock (B) Unlock

6) Insert the key to ignition switch, and open the driver’s side door. Press lock on power door lock. Check that the door is not locked.

(B) PI-00612

5. CHILD SAFETY LOCK SYSTEM (A) Door lock knob (B) Inner remote

1) Set the child safety lock on both rear doors to the lock position. 2) Close the rear doors completely. 3) Check that the lock levers of the rear doors are in the unlock position. Then, pull inner remote of rear doors to ensure that the doors will not open.

3) Close all the doors, and then press the lock on power door lock switch at driver’s side. Check that all doors including rear gate are locked.

(A)

(B) PI-00613

PI-00616

(A) Lock (B) Unlock

PI-5

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

4) Pull the outer handles to ensure that doors will open.

2) Make sure the latch is released by pulling the yellow trunk lid release handle in the direction of arrow.

6. OPEN/CLOSE OPERATION CHECKS OF TRUNK LID 1) Press the trunk opener switch for approx. one second to check for normal operation of the trunk lid.

PI-00610

8. LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS OF REAR GATE 1) Open and close the rear gate several times for smooth movement. 2) Operate the rear gate lever to check that the rear gate is locked and unlocked normally. (1) Remove the cover inside the rear gate.

PI-00617

2) Open and close the trunk lid several times for smooth movement. 3) Press the trunk opener lock button in the glove box.

PI-00605

(2) Operate the lever to check that the rear gate is locked and unlocked normally.

PI-00609

4) Check that the trunk lid will not open even when the trunk opener button is pressed.

7. TRUNK LID RELEASE HANDLE CAUTION: Do not check the trunk lid release handle when in the trunk. If the trunk lid release handle is defective, you may be trapped in. 1) Use a flat tip screwdriver. Slide in the screwdriver through the clearance at the lock assembly until a click sound is heard. This is the latch lock position.

PI-00606

9. FUEL LID OPENER LEVER Operate the fuel lid opener to check that the fuel lid is unlocked normally. Check that the filler cap is securely closed.

PI-00248

PI-6

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

10.ACCESSORY

13.BRAKE FLUID

Check that the following accessories are provided. • Owner’s manual • Warranty booklet • Maintenance note • Spare key • Key number plate • Jack • Tool set • Spare tire • Towing hook (Eye bolt) • Security ID plate

CAUTION: If the brake fluid is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. Check that the brake fluid level is normal. If the amount is insufficient, carry out a brake line test to identify brake fluid leaks and check the brake operation. After that, refill the brake fluid tank with the specified type of fluid.

14.ENGINE OIL CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. Check the engine oil amount. If the amount of oil is insufficient, check that no leaks are found. Then, add the necessary amount of the specified engine oil. • 2.5 L model

11.OPERATION CHECK OF FRONT HOOD LOCK RELEASE SYSTEM Operate the front hood lock release lever (A) to check that the front hood is unlocked normally.

(A)

(B)

(F)

(C) (A)

(E) (D)

PI-00607

Operate the lever (B) and check that the front hood is opened normally.

LU-02569

(A) (B) (C) (D) (E) (F)

(B)

Oil level gauge Engine oil filler cap “F” line “L” line Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt) Notch mark

• 3.6 L model PI-00608

12.BATTERY

(A)

Check the battery terminals to make sure that there are no rust or corrosions due to fluid leaks.

(B)

(C) (E) (D)

LU-02555

(A) (B) (C) (D) (E)

PI-00250

PI-7

Oil level gauge Engine oil filler cap “F” line “L” line Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

15.TRANSMISSION GEAR OIL

Check that the clutch fluid level is normal. If the amount of the fluid is insufficient, check that no leaks are found. Then, add the necessary amount of the specified fluid.

CAUTION: If transmission gear oil is spilt over the exhaust pipe, wipe it off with a cloth to avoid emitting smoke or causing a fire. Check that the transmission gear oil level is normal. If the amount of gear oil is insufficient, check that no leaks are found. Then add the necessary amount of the specified transmission gear oil.

(C)

(A) (B)

(A)

CL-00753

(B) (C)

(A) MAX. level (B) MIN. level (C) Reservoir tank

MT-02052

19.WINDOW WASHER FLUID Check that the window washer fluid level is normal. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of washer fluid.

(A) Oil level gauge (B) Upper level (C) Lower level

16.CVT FRONT DIFFERENTIAL GEAR OIL

20.FRONT HOOD LATCH

Check for no leakage of CVT front differential gear oil.

Close the front hood. Check that the front hood is securely latched.

17.ENGINE COOLANT

21.KEYLESS ENTRY SYSTEM

CAUTION: If the engine coolant is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. Check that the engine coolant level on the reservoir tank is normal. If the amount of engine coolant is insufficient, check that no leaks are found. Then, add the necessary amount of coolant with the specified concentration.

NOTE: The following inspections show the initial settings. When the settings are different from the initial settings, use Subaru Select Monitor to check the details of each setting for inspections. 1) Fully open all the door windows. 2) Remove the key from the ignition switch and close all the doors including rear gate. 3) Press the rear gate and trunk open button for at least one second. • Check if the trunk is opened and the hazard light blinks twice and the buzzer sounds twice. (Sedan model)

18.CLUTCH FLUID CAUTION: If the clutch fluid is spilt over the exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire.

PI-8

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

• Check if the rear gate is unlocked and the hazard light blinks twice and the buzzer sounds twice. (OUTBACK model)

7) Within a distance of 10 m from a vehicle, press keyless transmitter’s “LOCK” button three times within five seconds. Check that the horn honks once and that the hazard light blinks three times. 8) Move the power door lock switch to the lock position with one of doors (including the rear gate) opened. Next, close all the doors including rear gate. Check if all doors are locked and buzzer sounds once and the hazard light flashes once. 9) Check buzzer operation. The buzzer sounds when the doors are locked or unlocked. The buzzer can be turned off if desired. Turn the buzzer off or on with following procedure. (1) Close all the doors including rear gate, then remove the key from ignition key lock. (2) Press the power door lock switch to unlock and hold it until the operation is finished. (3) Insert the key into ignition key lock, and insert and remove the key in ignition key lock 5 times in 10 seconds. (4) When finished step (3), open and close the driver’s door once within 10 seconds.

PI-00640

4) Press the “LOCK” button on the keyless transmitter with one of the doors (including the rear gate and trunk) opened. Check if all doors are locked, hazard light blinks five times and the buzzer sounds five times and warning shows one of the doors (including the rear gate and trunk) open. 5) Close all the doors including rear gate and trunk. Press the “LOCK” button momentarily on the keyless transmitter. Check that all the doors (including rear gate and trunk) are locked, hazard light blinks once and buzzer sounds once.

NOTE: When opening and closing of the door is not available within 10 seconds, hazard light blinks once and the change over operation is cancelled. Retry from the step (1). (5) Hazard light blinks 3 times and the buzzer sound turns ON or OFF. 10) Press the “Panic” button of the keyless transmitter. Check if the alarm condition happens (horn sounds continuously, hazard light blinks, security indicator comes on). Check whether this condition lasts until any button on the keyless transmitter is pressed or lasts for 30 seconds.

PI-00639

6) Press the “UNLOCK” button momentarily on the keyless transmitter. Check that the driver’s door is unlocked and hazard light blinks twice and the buzzer sounds twice. And press the “UNLOCK” button momentarily again in 5 seconds. Check that all doors (including rear gate) are unlocked.

PI-00641

22.SECURITY SYSTEM (ALARM SYSTEM) NOTE: The following inspections show the initial settings. When the settings are different from the initial settings, use Subaru Select Monitor to check the details of each setting for inspections. 1) Fully open all the door windows.

PI-00640

PI-9

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

2) Remove the key from the ignition switch and close all the doors including rear gate. 3) Press the “LOCK” button momentarily on the keyless transmitter. All doors are locked, and buzzer sounds once, hazard blinks once, security indicator light blinks faster (five times per two seconds) for 30 seconds and goes slower (twice per two seconds), then the alarm system is in set condition.

23.SEAT 1) Check the seat surfaces for stains or dirt. 2) Check that each seat functions properly in sliding and reclining. Check that the seat position memory for driver’s power seat function properly. Check all available functions of the rear seat such as a trunk-through center armrest. 3) Check the passenger’s seat occupant detection system. (1) Turn the ignition switch to ON. (2) Check the ON and OFF of passenger’s airbag indicator light come on simultaneously for about 6 seconds and go off for 2 seconds, and then only OFF illuminates again. (A)

PI-00639

4) Press the “UNLOCK” button momentarily on the keyless transmitter. When the door of the driver’s seat is unlocked, the buzzer sounds twice, the hazard light flashes twice, the room light turns on and the security indicator light flashes once in three seconds, and the alarm system enters the release mode.

(B) PI-00618

(A) Indication for US (B) Indication for Canada

(3) Have a person weighing approximately 70 kg (155 lb) or more sit in the passenger’s seat, and check whether the passenger’s airbag indicator light illuminate or not. (4) Empty the passenger seat, then check whether the passenger side airbag indicator light OFF illuminates. PI-00640

5) Close all the doors including rear gate. Press the “LOCK” button momentarily on the keyless transmitter. When all the doors are locked, buzzer sounds once, hazard blinks once and the alarm system is in set condition in 30 seconds. 6) Unlock a door using the inner lock knob and open the door while the security system is in the set mode. Check if the alarm condition happens (horn sounds continuously, hazard light blinks, security indicator illuminates). Check if this condition lasts for a maximum of three minutes or until the “UNLOCK” button of the keyless transmitter is pressed. NOTE: The alarm condition will cease in 30 seconds once the door is closed. 7) When none of above is applicable, perform troubleshooting for the security system.

24.SEAT BELT 1) Check installation condition of seat belt. 2) Pull out the seat belt and then release it. Check that the belt retracts smoothly. 3) Check that the ALR seat belt operates normally. 4) CHECK SEAT BELT WARNING FUNCTION. (1) Turn the ignition switch to ON with the driver’s and passenger’s seat belt detached. (2) Check the driver’s and passenger’s seat belt warning light blink for approx. 6 seconds and the buzzer sounds intermittently. (3) Then, check the seat belt warning light illuminates and blinks repeatedly at a cycle of approx. 15 seconds. (If no passenger is on the passenger’s seat, the seat belt warning light on passenger’s seat does not operate.)

PI-10

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

25.TPMS

31.AIR CONDITIONER

1) Turn the ignition switch to ON, and check TPMS warning light for normal operation. • Normal operation (IG ON (light check))

Operate the air conditioner. Check that the A/C compressor operates normally and enough cooling is provided. NOTE: To prevent the insufficient lubrication of the air conditioner, operate the air conditioner for five minutes at idling.

ON OFF

32.CLOCK 2s IGN ON PI-00376

2) If the TPMS warning light display does not operate normally, check and repair the system.

26.IMMOBILIZER SYSTEM 1) Check that the engine starts with all keys that are equipped on vehicle. 2) 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing the key, check that the security indicator light is blinking. 3) For the model for Canada, execute Each System Check > Integ. unit mode > “SCU collation mode” on SSMIII to check [Collation OK (no error)] is displayed. NOTE: If malfunctions occur, refer to “IMMOBILIZER (DIAGNOSIS)”.

27.STARTING CONDITION Start the engine and check that the engine starts smoothly. If the battery voltage is low, recharge or replace the battery. If any noises are observed, immediately stop the engine and check and repair the abnormal components.

28.EXHAUST SYSTEM Listen to the exhaust noise to see if no exhaust gas leak or abnormal noises are observed.

29.INDICATOR LIGHT AND WARNING LIGHT

Check the clock for normal operations and enough accuracy. Check the fuel economy display switches by operating the knob on the meter. Also check there is no significant error on the outside temperature display.

33.AUDIO Check that all radio functions operate, the speakers emit sound properly and the noise is at an acceptable level. Also check the CD unit and AUX unit operations.

34.NAVIGATION SYSTEM 1) Check all display functions for normal operation. (Refer to the owner’s manual for the operation procedures.) 2) Check the map disc (DVD) are provided on vehicle. 3) Check that the navigation system operates normally. 4) Check that the rearview camera operates normally.

35.ACCESSORY POWER SUPPLY SOCKET 1) Check the operation of the front accessory power supply socket. 2) Check operation of the accessory power supply socket in console box.

36.LIGHTING SYSTEM 1) Check the headlight operation. 2) Check the stop light operation. 3) Check other lights for normal operations.

37.WIPER DEICER Check that the wiper deicer operates normally.

Check that all indicator lights and warning lights operate normally.

38.ILLUMINATION CONTROL Check that the illumination control operates normally.

30.HEATER & VENTILATION Operate the heater & ventilation system to check for normal airflow outlet control, air inlet control, airflow capacity and heating performance.

PI-11

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

39.WINDOW WASHER

42.SUNROOF

Check that the window washer system injects washer fluid to the specified area of the windshield and rear window glass shown in the figure.

Check that the sunroof operates normally.

Front injection position:

43.DOOR MIRROR Check that the remote control mirror operates normally.

44.PARKING BRAKE Check the parking brake operates properly by depressing brake pedal and pressing the electronic parking brake switch.

(A) (B)

45.BRAKE TEST (G) :(C) :(D)

(E)

Check the foot brake for normal operations.

(E) (F)

(F)

46.AT SHIFT CONTROL PI-00643

1) Turn the ignition switch to ON. 2) While brake pedal is not depressed, check if the select lever does not move from “P” range. 3) While brake pedal is depressed, check if the select lever moves from “P” range. 4) Set the select lever to other than “P” range. 5) When the ignition switch is turned to OFF, check if the ignition key switch cannot be removed. 6) Set the selector lever to “D” range and check the shifting while driving the vehicle.

(A) Hitting point center (B) Lower-side spray position center (C) Washer fluid elevation angle/dispersal angle lower limit (D) Washer fluid elevation angle/dispersal angle upper limit (E) Upper spray nozzle center of washer nozzle (F) 250 mm (9.84 in) (G) 23 mm (0.91 in)

92 mm (3.62 in)

57 mm (2.24 in)

Rear injection position:

56.5

PI-00611

47.MT SHIFT CONTROL PI-00646

40.WIPER Check the front and rear wipers for normal operations.

41.POWER WINDOW

1) Check for smooth operation to each position. Especially, shifting to 5th ←→ 6th, and then to Rev, check for any drag. 2) Check the slider returns to the original position by shifting to the Rev and then back in neutral while pulling up the slider.

• Operate the power window switches one by one to check that each of the power windows goes up and down without noises. • Check AUTO UP/AUTO DOWN operate properly by operating the power window switch on driver’s seat side. CAUTION: If battery has been removed, AUTO UP does not operate properly because initialized. In this case, perform the initial setting (reset A) and check AUTO UP operates properly.

PI-12

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

3) If the shift operation is not smooth, readjust the exposed length (a) of the MT gear select cable referring to the figure below. (a)

CAUTION: If the ATF is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. After selecting all positions (P, R, N, D), set the select lever in “P” range. Idle the engine for 1 or 2 minutes, and measure the ATF level. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified ATF.

(A) (B) (C)

(A)

5th

L

3rd

(A)

F

1st

F HOT

(B)

49.ATF LEVEL

(B) COLD L

(B)

(C)

AT-04217

2nd

4th

6th

(A) Level gauge (B) Upper level (C) Lower level

Rev (C) CS-01043

(a) (A) (B) (C)

Exposed length of MT gear select cable Extending exposed length of gear select cable Shrinking exposed length of gear select cable Reference for exposed length (a)

50.CVTF Check for leakage of CVTF.

51.AT FRONT DIFFERENTIAL OIL

• If 5th or 6th gear cannot be selected when cable is pressed to reverse lock bracket: → Extend the exposed length (a) of MT gear select cable. • If select lever does not move along the cranking line when it is operated from 4th to 5th gear: → Shorten the exposed length (a) of MT gear select cable.

48.CRUISE CONTROL Operate the cruise control system. Check that the system is activated and deactivated correctly.

Check for leakage of AT front differential oil.

52.POWER STEERING FLUID LEVEL CAUTION: If any power steering fluid is spilt over the exhaust pipe, wipe it off with a cloth to avoid emitting smoke or causing a fire. Check that the power steering fluid level is normal. If the amount is insufficient, check that no leaks are found. Then add the necessary amount of the specified power steering fluid.

HOT MAX COLD MAX HOT MIN COLD MIN PS-00463

53.OIL LEAKAGE Check entire areas of the vehicle for any trace of coolant/oil/fluid leaks.

PI-13

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Pre-delivery Inspection PRE-DELIVERY INSPECTION

54.WATER LEAK TEST Spray the vehicle with water using a hose and check that no water enters the passenger compartment. • Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry. • Close all the windows and doors securely. Close the hood and trunk lid before starting the test. • Spray the vehicle with water using a hose. The rate of water spray must be approx. 20 to 25 2 (5.3 — 6.6 US gal, 4.4 — 5.5 Imp gal) per minute. When spraying water on areas adjacent to the floor and wheel house, increase the pressure. When spraying water on areas other than the floor and wheel house, decrease the pressure. But the force of water must be made strong occasionally by pressing the end of the hose. NOTE: Be sure to keep the hose at least 10 cm (3.9 in) away from vehicle. Check the following areas. • Front window and body framework mating portion • Door mating portions • Glass mating portions • Rear quarter window mating portions • Rear window and body framework mating portion • Around roof drips If any dampness in the compartments is discovered after the water has been applied, carefully check all the areas that may have possibly contributed to the leak.

55.APPEARANCE CHECK 2 1) When vehicle body is covered with protective film (wrap guard), peel it off. NOTE: • It is easier to remove the wrap guard using steam. • For a vehicle left for a long time or at low temperature, sprinkle some water heated to 50 — 60°C (122 — 140°F) over the vehicle to raise its surface temperature before peeling off the wrap guard. Do not use the water heated to over 60°C (140°F). • If the adhesive remains exist on the coated surface, soak a flannel rag, etc. with a small amount of coating wax or solvent such as oil benzene and IPA, put the soaked cloth on the remains lightly, and then wipe them off with a flannel rag etc. • Keep solvent from touching the resin or rubber parts. Do not use coating wax or solvent while the component surface temperature is high due to hot weather etc.

• If the coated surface is swollen out due to seams or moisture, expose the vehicle to the sunlight for a few hours or heat the seam and swollen portions using a dryer etc. • Dispose of the peeled wrap guard as burnable industrial garbage. • If a yellow label is attached to the fog light lens, remove it. 2) Check the whole vehicle body for flaking paint, damage by transportation, corrosion, dirt, cracks or blisters. NOTE: • It is better to determine an inspection pattern in order to avoid missing an area, since the total inspection area is wide. • Do not repair the body paint unless absolutely necessary. Also, if the vehicle is in need of repair to remove scratches or corroded paint, the repair area must be limited to the minimum. Re-painting and spray painting must be avoided as much as possible. 3) Check each window glass for scratches carefully. Slight damage may be removed by polishing with cerium oxide. (Fill a cup half with cerium oxide, and add warm water to it. Then agitate the content until it turns to wax. Apply this wax to a soft cloth, and polish the glass with it.) 4) Check each portion of the vehicle body and underside components for the formation of rust. If rust is discovered, remove it with sandpaper of #80 to #180 and treat the surface with rust preventive. After this treatment is completed, flush the portion thoroughly, and prepare the surface for repair painting. 5) Check each portion of body and all of the exterior parts for deformation or distortion. Also, check each light lens for cracks. 6) Peel the protective tape, vinyl wrapping and identification seal attached to the following places. • Seat • Door trim • Floor carpet • Side sill • Front hood lock release lever • Edge rear • Rear wiper • Sedan rear combination light (Trunk lid opening portion) • Roof rail • Assist rail

PI-14

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PERIODIC MAINTENANCE SERVICES

PM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Page General Description ...................................................................................2 Schedule ....................................................................................................3 Engine Oil ...................................................................................................9 Engine Oil Filter ........................................................................................10 Spark Plug ................................................................................................11 V-belt ........................................................................................................12 Timing Belt ...............................................................................................13 Fuel Line ..................................................................................................15 Fuel Filter .................................................................................................16 Air Cleaner Element .................................................................................17 Cooling System ........................................................................................18 Engine Coolant .........................................................................................19 Clutch System ..........................................................................................20 Transmission Gear Oil .............................................................................21 Automatic Transmission Fluid ..................................................................22 CVTF ........................................................................................................23 Front & Rear Differential Gear Oil ............................................................24 Brake Line ................................................................................................25 Brake Fluid ...............................................................................................26 Disc Brake Pad and Disc .........................................................................27 Brake Lining and Drum ............................................................................28 Suspension ..............................................................................................29 Wheel Bearing ..........................................................................................32 Axle Boots & Joints ..................................................................................33 Tire Rotation .............................................................................................34 Steering System (Power Steering) ...........................................................35 A/C Filter ..................................................................................................37

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General Description PERIODIC MAINTENANCE SERVICES

1. General Description A: GENERAL DESCRIPTION Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they occur.

PM-2

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Schedule PERIODIC MAINTENANCE SERVICES

2. Schedule A: MAINTENANCE SCHEDULE 1 1. U.S. • Other than U5 model

1

Months 3 7.5 15 22.5 30 × 1,000 km 4.8 12 24 36 48 × 1,000 miles 3 7.5 15 22.5 30 Engine 3.6 L R R R R R oil 2.5 L R R R R

2

Engine oil filter

3 4 5

Spark plug Drive belt(s) Camshaft drive belt Fuel line Air cleaner element Cooling system Engine coolant

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

3.6 L 2.5 L

Clutch system Transmission oil ATF and CVTF Front and rear differential oil Brake line Brake fluid Disc brake pad and disc Parking brake Suspension Wheel bearing Axle boots and joints Tire rotation Steering system (Power steering) A/C filter

R

R R

R R

R R

R R

I I

Maintenance interval [Number of months or km (miles), whichever occurs first] 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 60 72 81.4 96 108 120 132 144 156 168 180 192 Remarks 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 R R R R R R R R R R R R R R R R R R R R R R R R Turbo model Note 6. R R R R R R R R R R R R R R R R R R R R R R R R Turbo model Note 6. R R I I R I I R

(I) R

(I) R

(I) R

I R

I I I Replace after the first 11 years or 220,000 km (137,500 miles), and every six years or 120,000 km (75,000 miles) thereafter I I I I I I I I I I I I I I I I I

I

I

I

I R I

I I

I I

I I

I

I

I

I I

I

I I

I

I

I I

I

I R I

I

I I (I) I I I

I

I

I

I R I

I I

I I

I I

I

I

I

I I

I

I I

Replace every 12 months or 15,000 km (9,300 miles).

Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation.

PM-3

I I

I

I I I I

Note 3.

I R I

I

I

Note 1. Note 2.

I I (I) I I

I I

Note 4.

Note 5.

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Schedule PERIODIC MAINTENANCE SERVICES NOTE: 1. This inspection is not required to maintain emission warranty eligibility and it does not affect the manufacturer’s obligations under EPA. 2. When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. 3. When CVTF is used under severe condition, to replace every 40,000 km (24,855 miles) is recommended. 4. A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicator appears when the remaining amount of tread is less than 1.6 mm (0.063 in). 5. When the A/C filter is installed. 6. For 2.5L turbo model, replace every 3.75 months or 6,000 km (3,750 miles).

PM-4

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Schedule PERIODIC MAINTENANCE SERVICES

• U5 model

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Maintenance interval [Number of months or km (miles), whichever occurs first] Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 To be continued to the next table. × 1,000 km 4.8 12 24 36 48 60 72 81.4 96 108 120 × 1,000 miles 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 Engine oil 3.6 L R R R R R R R R R R R 2.5 L R R R R R R R R R R Engine oil 3.6 L R R R R R R R R R R R filter 2.5 L R R R R R R R R R R Spark plug R Drive belt(s) I I Camshaft drive I I belt Fuel line (I) (I) Air cleaner eleR R ment Cooling system I I Engine coolant Replace after the first 11 years or 220,000 km (137,500 miles), and every six years or 120,000 km (75,000 miles) thereafter Clutch system I I I I I Transmission oil I I ATF and CVTF I I Front and rear difI I ferential oil Brake line I I I I I Brake fluid R R Disc brake pad I I I I I and disc Parking brake I I I I I Suspension I I I I I

19 Wheel bearing 20 Axle boots and joints 21 Tire rotation 22 Steering system (Power steering) 23 A/C filter

I I

I I

I I

I I

(I) I

I I

I I

I

I I

Remarks

Note 1. Note 2.

Note 3.

I I

I I

Replace every 12 months or 15,000 km (9,300 miles).

Note 4.

Note 5.

Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: 1. This inspection is not required to maintain emission warranty eligibility and it does not affect the manufacturer’s obligations under EPA. 2. When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. 3. When CVTF is used under severe condition, to replace every 40,000 km (24,855 miles) is recommended. 4. A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicator appears when the remaining amount of tread is less than 1.6 mm (0.063 in). 5. When the A/C filter is installed.

PM-5

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Schedule PERIODIC MAINTENANCE SERVICES

Months

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

× 1,000 km × 1,000 miles Engine oil Engine oil filter Spark plug Drive belt(s) Camshaft drive belt Fuel line Air cleaner element Cooling system Engine coolant Clutch system Transmission oil ATF and CVTF Front and rear differential oil Brake line Brake fluid Disc brake pad and disc Parking brake Suspension Wheel bearing Axle boots and joints Tire rotation Steering system (Power steering) A/C filter

Maintenance interval [Number of months or km (miles), whichever occurs first] Continued from previous 82.5 90 97.5 105 112.5 120 127.5 135 142.5 150 table 132 144 156 168 180 192 204 216 228 240 82.5 90 97.5 105 112.5 120 127.5 135 142.5 150 R R R R R R R R R R R R R R R R R R R R R I R I I R I (I) I (I) R R R I I I Replace after the first 11 years or 220,000 km (137,500 miles), and every six years or 120,000 km (75,000 miles) thereafter I I I I I I I I I I I I I

I

I R I

I

I I

I I

I I I

I

I

I I I

I

I R I

I

I I (I) I I I

I I

Replace every 12 months or 15,000 km (9,300 miles).

I I I

Note 1. Note 2.

Note 3.

I R I

I

I

Remarks

I

I I (I) I I I

Note 4.

Note 5.

Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: 1. This inspection is not required to maintain emission warranty eligibility and it does not affect the manufacturer’s obligations under EPA. 2. When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. 3. When CVTF is used under severe condition, to replace every 40,000 km (24,855 miles) is recommended. 4. A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicator appears when the remaining amount of tread is less than 1.6 mm (0.063 in). 5. When the A/C filter is installed.

PM-6

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Schedule PERIODIC MAINTENANCE SERVICES

2. CANADA

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Maintenance interval [Number of months or km (miles), whichever occurs first] Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 × 1,000 km 4.8 12 24 36 48 60 72 81.4 96 108 120 132 144 156 168 180 192 Remarks × 1,000 miles 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120 Engine oil 3.6 L R R R R R R R R R R R R R R R R R 2.5 L R R R R R R R R R R R R R R R R R Engine oil 3.6 L R R R R R R R R R R R R R R R R R filter 2.5 L R R R R R R R R R R R R R R R R R Spark plug R R Drive belt(s) I I I R Camshaft drive I I I R belt Fuel line (I) (I) (I) I Note 1. Air cleaner eleR R R R Note 2. ment Cooling system I I I I Engine coolant Replace after the first 11 years or 220,000 km (137,500 miles), and every six years or 120,000 km (75,000 miles) thereafter Clutch system I I I I I I I I Transmission oil I I I I ATF and CVTF I I I I Note 3. Front and rear difI I I I ferential oil Brake line I I I I I I I I Brake fluid R R R R Disc brake pad I I I I I I I I and disc Parking brake I I I I I I I I Suspension I I I I I I I I Wheel bearing (I) (I) Axle boots and I I I I I I I I joints Tire rotation I I I I I I I I I I I I I I I I Note 4. Steering system I I I I I I I I (Power steering) A/C filter Replace every 12 months or 15,000 km (9,300 miles). Note 5.

Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: 1. This inspection is not required to maintain emission warranty eligibility and it does not affect the manufacturer’s obligations under EPA. 2. When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. 3. When CVTF is used under severe condition, to replace every 40,000 km (24,855 miles) is recommended. 4. A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicator appears when the remaining amount of tread is less than 1.6 mm (0.063 in). 5. When the A/C filter is installed.

PM-7

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Schedule PERIODIC MAINTENANCE SERVICES

B: MAINTENANCE SCHEDULE 2 Item Engine oil

Engine oil filter

Fuel line

Transmission oil

ATF

CVTF Front & rear differential gear oil Brake line

Brake fluid

Disc brake pad and disc Parking brake

Suspension

Axle boots and joints Steering system (Power steering)

Repeat rough/muddy road drive

Extremely cold weather area

Salt or other corrosive used or coastal area

High humidity or mountain area

Maintenance interval

Repeat short distance drive

3.75 months 6,000 km 3,750 miles 3.75 months 6,000 km 3,750 miles 7.5 months 12,000 km 7,500 miles 15 months 24,000 km 15,000 miles 15 months 24,000 km 15,000 miles 40,000 km 24,855 miles

R

R

R

R

R

R

15 months 24,000 km 15,000 miles 7.5 months 12,000 km 7,500 miles 15 months 24,000 km 15,000 miles 7.5 months 12,000 km 7,500 miles 7.5 months 12,000 km 7,500 miles 7.5 months 12,000 km 7,500 miles 7.5 months 12,000 km 7,500 miles 7.5 months 12,000 km 7,500 miles

Repeat towing trailer

I

R

R

R R

I

R

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

PM-8

I

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Engine Oil PERIODIC MAINTENANCE SERVICES

3. Engine Oil A: INSPECTION Refer to “LU” section for engine oil inspection.

B: REPLACEMENT Refer to “LU” section for engine oil replacement.

PM-9

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Engine Oil Filter PERIODIC MAINTENANCE SERVICES

4. Engine Oil Filter A: REPLACEMENT Refer to “LU” section for engine oil filter replacement.

PM-10

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Spark Plug PERIODIC MAINTENANCE SERVICES

5. Spark Plug A: REPLACEMENT Refer to “IG” section for spark plug replacement.

PM-11

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V-belt PERIODIC MAINTENANCE SERVICES

6. V-belt A: INSPECTION Refer to “ME” section for V-belt inspection.

B: REPLACEMENT Refer to “ME” section for V-belt replacement.

PM-12

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Timing Belt PERIODIC MAINTENANCE SERVICES

7. Timing Belt

2. SOHC MODEL (OTHER INSPECTIONS)

A: INSPECTION 1. SOHC MODEL (INSPECTION OF TIMING BELT POSITION) 1) Remove the timing belt cover (LH). 2) Rotate the crank pulley to set #1 cylinder piston to top dead center of compression stroke and check the followings. (1) Confirm that the arrow (A) of camshaft pulley LH points in an upward direction.

1) Remove the front timing belt cover and timing belt cover (LH). 2) While cranking engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt with new part as needed. 3) When the side part of timing belt is abnormally worn (fluff or jumping out of core) or damaged, check the idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt with new part. 4) Install the front timing belt cover and timing belt cover (LH).

3. DOHC MODEL (INSPECTION OF TIMING BELT POSITION) (A)

PM-00531

(2) Remove the sealing rubber (B) of timing belt cover RH. (3) Confirm that the arrow (C) of camshaft pulley RH points in an upward direction.

1) Remove the timing belt cover (LH) and (RH). 2) Rotate the crank pulley to align single line mark (A) on the intake camshaft pulley RH with notch (B) on timing belt cover and check the followings. (1) Confirm that the double line marks (C) on intake camshaft pulley RH and exhaust camshaft pulley RH are aligned. (2) Confirm that the single line mark (D) on exhaust camshaft pulley RH and notch (E) on timing belt cover are aligned. (B)

(A)

(B)

(C)

(C)

(E)

(D) PM-00532

PM-00533

3) If the camshaft pulley or timing belt position is not appropriate, check the faulty part and repair or replace as required.

PM-13

(3) Confirm that the single line mark (A) on intake camshaft pulley LH and notch (B) on timing belt cover are aligned. (4) Confirm that the double line marks (C) on intake camshaft pulley LH and exhaust camshaft pulley LH are aligned.

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Timing Belt PERIODIC MAINTENANCE SERVICES

(5) Confirm that the single line mark (D) on exhaust camshaft pulley LH and notch (E) on timing belt cover are aligned. (B)

B: REPLACEMENT Refer to “ME” section for timing belt replacement.

(A)

(C)

(E)

(D)

PM-00534

3) If the camshaft pulley position is not appropriate, check the faulty part and repair or replace as required.

4. DOHC MODEL (OTHER INSPECTIONS) 1) Remove the timing belt cover (LH). 2) While cranking engine at least four rotations, check the timing belt back surface for cracks or damage. Replace the faulty timing belt with new part as needed. 3) When the side part of timing belt (arrow direction shown in the figure) is abnormally worn (fluff or jumping out of core) or damaged, check the idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace the worn timing belt with new part.

PM-00343

4) Install the timing belt cover (LH).

PM-14

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Fuel Line PERIODIC MAINTENANCE SERVICES

8. Fuel Line A: INSPECTION The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose band, etc. If faulty parts are found, repair or replace them.

PM-15

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Fuel Filter PERIODIC MAINTENANCE SERVICES

9. Fuel Filter A: REPLACEMENT Refer to “FU” section for fuel filter replacement.

B: INSPECTION Replace if the filter is clogged, or time for replacement has come.

PM-16

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Air Cleaner Element PERIODIC MAINTENANCE SERVICES

10.Air Cleaner Element A: REPLACEMENT Refer to “IN” section for air cleaner element replacement.

PM-17

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Cooling System PERIODIC MAINTENANCE SERVICES

11.Cooling System A: INSPECTION 1. RADIATOR Refer to “CO” section for radiator inspection.

2. RADIATOR CAP Refer to “CO” section for radiator cap inspection.

3. COOLING FAN Check the radiator fan operates using Subaru Select Monitor, when the coolant temperature exceeds 98°C (208°F). If it does not operate, check the radiator fan system.

4. COOLING SYSTEM Start the engine, and then inspect that it does not overheat or it is not cooled excessively. If it overheats or it is cooled excessively, check the cooling system.

PM-18

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Engine Coolant PERIODIC MAINTENANCE SERVICES

12.Engine Coolant A: REPLACEMENT Refer to “CO” section for engine coolant replacement.

PM-19

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Clutch System PERIODIC MAINTENANCE SERVICES

13.Clutch System A: INSPECTION AND ADJUSTMENT Refer to “CL” section for inspection and adjustment of clutch system.

PM-20

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Transmission Gear Oil PERIODIC MAINTENANCE SERVICES

14.Transmission Gear Oil A: INSPECTION Refer to “6MT” section for transmission gear oil inspection.

B: REPLACEMENT Refer to “6MT” section for transmission gear oil replacement.

PM-21

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Automatic Transmission Fluid PERIODIC MAINTENANCE SERVICES

15.Automatic Transmission Fluid A: INSPECTION Refer to “5AT” section for ATF inspection.

B: REPLACEMENT Refer to “5AT” section for ATF replacement.

PM-22

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CVTF PERIODIC MAINTENANCE SERVICES

16.CVTF A: REPLACEMENT Refer to “CVT” section for CVTF replacement.

PM-23

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Front & Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES

17.Front & Rear Differential Gear Oil A: INSPECTION 1. FRONT DIFFERENTIAL (MT MODEL) Front differential gear oil of MT model lubricates the transmission and differential together. Refer to “Transmission Gear Oil” for replacement procedure.

2. FRONT DIFFERENTIAL (AT MODEL) Refer to “5AT” section for inspection of AT model front differential gear oil.

3. REAR DIFFERENTIAL Refer to “DI” section for rear differential gear oil inspection.

B: REPLACEMENT 1. FRONT DIFFERENTIAL (MT MODEL) Front differential gear oil of MT model lubricates the transmission and differential together. Refer to “6MT” section for replacement procedure.

2. FRONT DIFFERENTIAL (AT MODEL) Refer to “5AT” section for front differential gear oil replacement.

3. FRONT DIFFERENTIAL (CVT MODEL) Refer to “CVT” section for front differential gear oil replacement.

4. REAR DIFFERENTIAL Refer to “DI” section for rear differential gear oil replacement.

PM-24

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Brake Line PERIODIC MAINTENANCE SERVICES

18.Brake Line

3. BRAKE SERVO SYSTEM

A: INSPECTION 1. BRAKE LINE 1) Check for scratches, swelling, corrosion, traces of fluid leakage on the brake hoses or pipe joints. 2) Make sure that brake pipes/hoses do not interfere with adjacent parts and there is no loose connector/clamp during driving. 3) Check any trace of fluid leakage, scratches, etc. on master cylinder, wheel cylinder and hydraulic unit. NOTE: • When the brake fluid level in the reservoir tank is lower than specified limit, the brake warning light on the combination meter will illuminate. • Visually check the brake hose for damage. (Use a mirror where it is difficult to see)

1) With the engine off, depress the brake pedal several times applying the same pedal force. Check that the travel distance should not change. 2) With the brake pedal depressed, start the engine. Check that the pedal moves slightly toward the floor. 3) With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds. Check that the pedal height does not change. 4) A check valve is built into the brake booster nipple. Disconnect the vacuum hose to inspect function of check valve. Check that check valve ventilates from booster side to engine side. Also, check that there is no ventilation from engine side to booster side.

(C)

(A)

(3) (2)

(1)

(D)

(B) PM-00260

(A) (B) (C) (D)

PM-00465

(1) Front brake hose (2) Front brake pipe (3) Clamp

(3)

Brake booster Check valve Engine side Brake booster side

5) Check the vacuum hose for cracks or other damage. CAUTION: When installing the vacuum hose on the engine and brake booster, do not use soapy water or lubricating oil on their connections. 6) Check that the vacuum hose is securely tightened.

(1)

(2)

PM-00466

(1) Brake pipe (2) Rear brake hose (3) Clamp

2. SERVICE BRAKE Refer to “BR” section for foot brake inspection.

PM-25

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Brake Fluid PERIODIC MAINTENANCE SERVICES

19.Brake Fluid A: INSPECTION Refer to “BR” section for brake fluid inspection.

B: REPLACEMENT Refer to “BR” section for brake fluid replacement.

PM-26

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Disc Brake Pad and Disc PERIODIC MAINTENANCE SERVICES

20.Disc Brake Pad and Disc A: INSPECTION Refer to “BR” section for disc brake pad and disc inspection.

PM-27

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Brake Lining and Drum PERIODIC MAINTENANCE SERVICES

21.Brake Lining and Drum A: INSPECTION Refer to “PB” section for brake lining inspection.

B: ADJUSTMENT Refer to “PB” section for brake lining adjustment.

PM-28

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Suspension PERIODIC MAINTENANCE SERVICES

22.Suspension

NOTE: When the front arm ball joint is removed or replaced, check the toe-in of front wheel. If it is not within the specified value, adjust the toe-in.

A: INSPECTION 1. FRONT SUSPENSION BALL JOINT 1) Lift up the vehicle until front wheels are off ground. 2) Grasp the bottom of tire and move it in and out in axial direction. If movement (B) is observed between the brake disc cover (A) and end of front arm (D), ball joint (C) may be excessively worn.

(A)

PM-00059

(A) Dust boot

2. REAR SUSPENSION BALL JOINT

(A)

(D) (C)

(B) PM-00258

3) Next, grasp the end of front arm (C) and move it up and down. If movement (A) between the housing (D) and front arm (C) boss is observed, ball joint (B) may be excessively worn.

1) Lift up the vehicle until rear wheels are off ground. 2) Grasp the bottom of tire and move it in and out in axial direction. 3) If movement is observed between the brake disc cover (A) and end of front lateral link (B), ball joint may be excessively worn.

(D)

(A) (C)

(A) (B)

(B)

PM-00259

4) If the relative movement is observed in the preceding two steps, remove and inspect the ball joint. If the free play exceeds standard value, replace the ball joint. 5) Damage of dust boot Visually inspect the ball joint dust boot. Replace if ball joint is damaged.

PM-00548

4) Grasp the end of front lateral link (B) and move it up and down. If movement is observed between the housing (C) and front lateral link (B) boss, ball joint may be excessively worn.

(C)

(B) PM-00547

5) If the movement related to the previous two steps is observed, replace the front lateral link.

PM-29

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Suspension PERIODIC MAINTENANCE SERVICES

6) Damage of dust boot Visually inspect the ball joint dust boot. Replace if front lateral link is damaged. 7) Check upper arm ball joint in the same manner.

• Rear suspension bushing

(A)

PM-00549

(A) Upper arm ball joint

3. FRONT, REAR SUSPENSION BUSHING Apply pressure with tire lever etc, and inspect the bushing for excessive wear or damage. Replace the bushings if faulty. • Front suspension bushing

PM-00551

4. WHEEL ARCH HEIGHT Refer to “FS” section for wheel arch height inspection.

5. WHEEL ALIGNMENT Measure and adjust the front and rear wheel alignment at a time. Refer to “FS” section for measurement and adjustment of wheel alignment.

6. OIL LEAKAGE OF STRUT AND SHOCK ABSORBER Visually inspect the front strut and rear shock absorber for oil leakage. Replace the front strut and rear shock absorber if oil leaks excessively.

7. TIGHTNESS OF BOLTS AND NUTS

PM-00550

Check the bolts and nuts for looseness. Retighten the bolts and nuts to specified torque. If the selflocking nuts and bolts are removed, replace them with new parts.

PM-30

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Suspension PERIODIC MAINTENANCE SERVICES

8. DAMAGE TO SUSPENSION PARTS Check the following parts and the fastening portion of the vehicle body for deformation or excessive rusting which impairs the suspension. Thoroughly remove the deposits of the lower spring seat of strut where dust or mud are likely piled up. If necessary, replace the damaged parts with new parts. If minor rust formation, pitting, etc. are noted, remove the rust and take rust prevention measure. • Front suspension • Front arm • Cradle • STRUT • Rear suspension • Sub frame • Front lateral link • Rear lateral link • Upper arm • Trailing link • Shock absorber • In the area where salt is sprayed to melt snow on a road in winter, check suspension parts for damage caused by rust every 12 months after lapse of 60 months. Take rust prevention measures as required.

PM-31

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Wheel Bearing PERIODIC MAINTENANCE SERVICES

23.Wheel Bearing

6) While supporting rear drive shaft horizontally with one hand, turn the hub with the other hand to check for noise or binding. If the hub is noisy or binds, replace the rear axle.

A: INSPECTION 1. FRONT WHEEL BEARING NOTE: Inspect the condition of front wheel bearing grease. 1) Jack-up the front side of vehicle. 2) While holding the front wheel by hand, swing it in and out to check bearing free play. 3) Loosen the wheel nuts, and remove the front wheel. 4) If the bearing free play exists in step 2) above, attach a dial gauge to the hub and measure axial play in axial direction.

Service limit: Straight-ahead position within 0.05 mm (0.0020 in) 5) Remove the bolts and self-locking nuts, and extract the front arm from front crossmember. 6) Remove the AAR of front drive shaft from transmission. 7) While supporting the front drive shaft horizontally with one hand, turn the hub with the other hand to check for noise or binding. If the hub is noisy or binds, replace the front axle.

PM-00173

2. REAR WHEEL BEARING 1) Jack-up the rear side of vehicle. 2) While holding the rear wheel by hand, swing it in and out to check bearing free play. 3) Loosen the wheel nuts, and remove the rear wheel. 4) If the bearing free play exists in step 2) above, attach a dial gauge to the hub and measure axial play in axial direction.

Service limit: Straight-ahead position within 0.05 mm (0.0020 in) 5) Remove the DOJ of rear drive shaft from rear differential.

PM-32

PM-00173

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Axle Boots & Joints PERIODIC MAINTENANCE SERVICES

24.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace with new part. • Front (A)

PM-00174

• REAR

(B) PM-00175

2. PROPELLER SHAFT Inspect the propeller shaft for damage or failure. If faulty, replace with new part.

PM-33

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Tire Rotation PERIODIC MAINTENANCE SERVICES

25.Tire Rotation A: INSPECTION Refer to “WT” section for tire rotation procedures.

PM-34

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Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES

26.Steering System (Power Steering)

2. STEERING SHAFT JOINT

A: INSPECTION 1. STEERING WHEEL 1) Set the steering wheel in a straight-ahead position, and check the wheel spokes to make sure they are correctly set in their specified positions. 2) Lightly turn the steering wheel to the left and right to determine the point where front wheels start to move. Measure the distance of the movement of steering wheel (periphery).

Steering wheel free play: 0 — 17 mm (0 — 0.67 in)

When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and check it for any play and yawing torque (at the point of the crossing direction). Also inspect for any damage to sealing or worn serrations. If the joint is loose, retighten the mounting bolts to the specified torque.

Tightening torque: 24 N·m (2.4 kgf-m, 17.4 ft-lb)

3. GEARBOX 1) Set the steering wheel in the straight position, then rotate it 90° in both the left and right directions. While steering wheel is being rotated, check the gearbox for looseness.

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb)

(1)

PM-00545

(1) Steering wheel free play

PS-01067

Move the steering wheel vertically toward the shaft to check if there is play in the direction.

Play limit: 0.5 mm (0.020 in) 3) Drive the vehicle and check the following items. (1) Steering force: The effort required for steering should be smooth and even at all points, and should not vary. (2) Pulled to one side: Steering wheel should not be pulled to one side while driving on a level surface. (3) Wheel runout: Steering wheel should not show any sign of runout. (4) Return status: Steering wheel should return to its original position after it has been turned and then released.

2) Check the boot for damage, cracks or deterioration. 3) With the vehicle stopped on a level surface, quickly turn the steering wheel to the left and right. While steering wheel is being rotated, check the gear backlash. If any noise is noticed, adjust the gear backlash.

PM-35

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Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES

4. TIE-ROD 1) Check the tie-rod and tie-rod ends for bends, scratches or other damage.

(B) (A) PM-00394

(A) Tie-rod end (B) Tie-rod

2) Confirm that the connections of knuckle ball joints for play, and then check for damage on dust boots and free play of ball studs. If castle nut is loose, retighten it to the specified torque, then tighten further up to a maximum of 60° until the cotter pin hole is aligned.

Tightening torque: 27 N·m (2.75 kgf-m, 19.9 ft-lb) 3) Check the lock nut on the tie-rod end for tightness. If it is loose, retighten it to the specified torque. Tightening torque: 85 N·m (8.7 kgf-m, 62.7 ft-lb)

5. GEARBOX BOOTS Inspect both sides of the gearbox boot as follows, and correct the defects if necessary. 1) The (A) and (B) positions of the gearbox boot are fitted in (A) and (C) grooves of gearbox and the rod. 2) Clips are fitted outside of positions (A) and (B) of boot. 3) Check that there is no cracks or holes in the boot. NOTE: Rotate (B) position of gearbox boot against the torsion produced by the adjustment of toe-in etc. Apply grease to the groove (C). (C)

(B) (A) PM-00090

PM-36

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A/C Filter PERIODIC MAINTENANCE SERVICES

27.A/C Filter A: REPLACEMENT Refer to “AC” section for A/C filter replacement.

PM-37

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A/C Filter PERIODIC MAINTENANCE SERVICES

PM-38

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2010 LEGACY SERVICE MANUAL

QUICK REFERENCE INDEX

ENGINE 1 SECTION

This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of 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.

FUEL INJECTION (FUEL SYSTEMS)

FU(H4SO)

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(H4SO)

INTAKE (INDUCTION)

IN(H4SO)

MECHANICAL

ME(H4SO)

EXHAUST

EX(H4SO)

COOLING

CO(H4SO)

LUBRICATION

LU(H4SO)

SPEED CONTROL SYSTEMS

SP(H4SO)

IGNITION

IG(H4SO)

STARTING/CHARGING SYSTEMS

SC(H4SO)

ENGINE (DIAGNOSTICS)

EN(H4SO)(diag)

GENERAL DESCRIPTION

GD(H4SO)

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD.

G2460BE2

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FUEL INJECTION (FUEL SYSTEMS)

FU(H4SO) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Page General Description ...................................................................................2 Throttle Body ............................................................................................14 Intake Manifold .........................................................................................16 Engine Coolant Temperature Sensor .......................................................21 Crankshaft Position Sensor ......................................................................22 Camshaft Position Sensor ........................................................................24 Knock Sensor ...........................................................................................26 Throttle Position Sensor ...........................................................................28 Mass Air Flow and Intake Air Temperature Sensor .................................29 Manifold Absolute Pressure Sensor .........................................................30 EGR Valve ...............................................................................................31 Fuel Injector .............................................................................................32 Variable Valve Lift Diagnosis Oil Pressure Switch ...................................33 Oil Temperature Sensor ...........................................................................34 Front Oxygen (A/F) Sensor ......................................................................35 Rear Oxygen Sensor ................................................................................37 Engine Control Module (ECM) .................................................................39 Main Relay ...............................................................................................40 Fuel Pump Relay ......................................................................................42 Electronic Throttle Control Relay .............................................................44 Fuel ..........................................................................................................46 Fuel Tank .................................................................................................48 Fuel Filler Pipe .........................................................................................55 Fuel Pump ................................................................................................58 Fuel Level Sensor ....................................................................................60 Fuel Sub Level Sensor .............................................................................62 Fuel Filter .................................................................................................64 Fuel Delivery and Evaporation Lines .......................................................66 Fuel System Trouble in General ..............................................................71

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General Description FUEL INJECTION (FUEL SYSTEMS)

1. General Description A: SPECIFICATION Fuel tank

Fuel pump

Capacity Install locations Type Shutoff discharge pressure Discharge rate

Fuel filter

70 2 (18.5 US gal, 15.4 Imp gal) Under rear seat Impeller 677 kPa (6.9 kgf/cm2, 98.2 psi) or less 105 2 (27.7 US gal, 23.1 Imp gal) [12 V at 300 kPa (3.06 kgf/cm2, 43.5 psi)] In-tank type

FU(H4SO)-2

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General Description FUEL INJECTION (FUEL SYSTEMS)

B: COMPONENT 1. INTAKE MANIFOLD T3

T3

(3) (4) T2 T1 (7)

(8) (5)

(11) (9)

(12) T2 (1)

(10) (9)

(6)

(10)

(9) (9) (10)

(2)

(10)

(2)

FU-05090

(1) (2) (3) (4) (5) (6)

Intake manifold Gasket Intake manifold protector RH Intake manifold protector LH Fuel gallery RH Fuel gallery LH

(7) (8) (9) (10) (11) (12)

Fuel pipe Fuel delivery pipe Injector O-ring Cap Clip

FU(H4SO)-3

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 19 (1.9, 14.0) T3: 25 (2.5, 18.4)

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General Description FUEL INJECTION (FUEL SYSTEMS)

2. AIR INTAKE SYSTEM

T3

(1) (12) T2 (13)

(26) (17)

(18)

(14)

T1

(15)

(4)

T2

(14)

(25) (2)

(5) (3)

(16) (18)

T2 (28)

T2 (6)

(24)

A

(18)

A (24)

A

(24) (19) (8) (10) T2

(18) (11)

(21)

T2 (7) (10)

(20) (22)

(27)

(9)

T2

(23) T4

FU-05091

(1)

Throttle body

(13)

PCV valve

(25)

(2) (3) (4)

Gasket Multi-function duct Manifold absolute pressure sensor

(14) (15) (16)

Clip PCV hose ASSY Clip

(26) (27) (28)

(5) (6)

O-ring Gasket

(17) (18)

Heater hose A Clip

(7) (8) (9) (10) (11)

PCV pipe PCV hose A PCV hose B Clip PCV hose C

(19) (20) (21) (22) (23)

Heater hose B EGR valve Gasket Gasket EGR pipe adapter

(12)

PCV hose D

(24)

Evaporation hose

FU(H4SO)-4

Purge control solenoid valve (U6 model) Bracket Engine harness Purge control solenoid valve (U5 model)

Tightening torque:N·m (kgf-m, ft-lb) T1: 2 (0.2, 1.5) T2: 6.4 (0.7, 4.7) T3: 8 (0.8, 5.9) T4: 19 (1.9, 14.0)

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General Description FUEL INJECTION (FUEL SYSTEMS)

3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS

T1

T2

(1)

(2)

T1

(4)

(3) T1 FU-04926

(1) (2)

Crankshaft position sensor Knock sensor

(3) (4)

Camshaft position sensor Camshaft position sensor support

FU(H4SO)-5

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 24 (2.4, 17.7)

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General Description FUEL INJECTION (FUEL SYSTEMS)

4. FUEL TANK (23)

T1

(8)

T1 T1

(7) (14)

A

B (24)

(24)

(9)

(12)

(24) (10) (1) C

(11)

(25)

(15) (13)

(24) T4 (2) B

(3)

A

T4 (17)

(16) (16)

T4

(6) (16) T3 C

T3 T3

(4) (18) (5)

(19)

(16)

(20) (22)

(21) T2

T3

(22) T2

(22)

T2

(22) T2

T3

FU-05148

FU(H4SO)-6

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General Description FUEL INJECTION (FUEL SYSTEMS) (1) (2)

Fuel tank Fuel tank band RH

(12) (13)

Fuel sub level sensor upper plate Fuel sub level sensor gasket

(23) (24)

Rubber cap Cushion

(3) (4)

Fuel tank band LH Fuel delivery tube

(14) (15)

Fuel sub level sensor protector Fuel sub level sensor filter

(25)

Cushion

(5) (6) (7) (8) (9) (10)

Tube clamp Fuel sub delivery tube Fuel pump ASSY Fuel pump upper plate Fuel pump gasket Fuel sub level sensor upper plate cushion Fuel sub level sensor

(16) (17) (18) (19) (20) (21)

Retainer Stopper Heat shield cover Fuel tank protector RH Fuel tank protector LH Clip

Tightening torque:N·m (kgf-m, ft-lb) T1: 4.4 (0.4, 3.2) T2: 9 (0.9, 6.6) T3: 18 (1.8, 13.3) T4: 33 (3.4, 24.3)

(22)

Self-locking nut

(11)

FU(H4SO)-7

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General Description FUEL INJECTION (FUEL SYSTEMS)

5. FUEL LINE (20)

(23)

T2

(22) F

G

(28)

T1 (1)

(19)

F

G

(18)

(24)

(27)

F

H

(30) (1)

(25)

I

T4

(14) H

(29) T1 (1) (13) (1)

(26)

(17)

(21)

(1)

(16) F (15) I

(1) (12) (11)

(10) (1)

C

T2

(1)

T2 (9) (4)

(1) C (1)

(2) (8) (1) (1)

A (3)

B

(7)

A B

T3

(5)

(6)

FU-05092

FU(H4SO)-8

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General Description FUEL INJECTION (FUEL SYSTEMS) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

Clip Fuel delivery hose Connect check cover Evaporation hose Fuel hose clamp Bracket Fuel pipe ASSY Purge hose A Purge pipe Purge hose B Connector Air vent hose A

(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)

Circulate tube Air vent tube Circulate hose Vent tube Drain valve Canister Drain filter Canister protector Charge tube Canister drain tube Drain tube ASSY Clamp

FU(H4SO)-9

(25) (26) (27) (28) (29) (30)

Fuel filler hose Clamp Fuel tank pressure sensor bracket Pressure hose Fuel tank pressure sensor Vacuum hose

Tightening torque:N·m (kgf-m, ft-lb) T1: 2.5 (0.3, 1.8) T2: 7.35 (0.7, 5.4) T3: 7.5 (0.8, 5.5) T4: 8 (0.8, 5.9)

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General Description FUEL INJECTION (FUEL SYSTEMS)

6. FUEL FILLER PIPE (3) (1) (2) (4)

(5) (10)

(6)

(11)

T3

(10) (12)

(13)

(7) (14)

T3 (8)

T2

T1

(8)

(9)

(15) T3 FU-05061

(1) (2) (3) (4) (5) (6) (7)

Fuel filler cap Fuel filler pipe protector Clip Neck holder A Neck holder B Fuel filler pipe Fuel filler pipe bracket A

(8) (9) (10) (11) (12) (13) (14)

Fuel filler pipe bracket B Fuel filler pipe bracket C Clip Evaporation hose Grommet Evaporation pipe Evaporation pipe protector

FU(H4SO)-10

(15)

Grommet

Tightening torque:N·m (kgf-m, ft-lb) T1: 1 (0.1, 0.7) T2: 7.35 (0.7, 5.4) T3: 7.5 (0.8, 5.5)

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General Description FUEL INJECTION (FUEL SYSTEMS)

7. FUEL PUMP (1) B (3)

A

B

(4)

(2) (2)

(5)

A (6)

A (7)

(11)

(10)

(8)

(11) (9)

FU-08400

(1)

Fuel filter assembly

(5)

Fuel pump

(9)

(2)

Pump module spring

(6)

Support rubber cushion

(10)

(3) (4)

Fuel pump harness Gasket spacer

(7) (8)

Fuel pump holder Fuel chamber ASSY

(11)

FU(H4SO)-11

Fuel level sensor (model with fuel level sensor bent in 3 locations) Fuel level sensor (model with fuel level sensor bent in 2 locations) Fuel temperature sensor

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General Description FUEL INJECTION (FUEL SYSTEMS)

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. • Place “NO OPEN FLAMES” signs near the working area. • Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can be spilled. If the oil spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing fuel.

FU(H4SO)-12

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General Description FUEL INJECTION (FUEL SYSTEMS)

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 1B022XU0

DESCRIPTION SUBARU SELECT MONITOR III KIT

REMARKS Used for draining fuel and each inspection.

ST1B022XU0

18471AA000

FUEL PIPE ADAPTER

Used for draining fuel.

42099AE000

QUICK CONNECTOR RELEASE

Used for disconnecting quick connector of the engine compartment.

ST18471AA000

ST42099AE000

2. GENERAL TOOL TOOL NAME Circuit tester Oscilloscope

REMARKS Used for measuring resistance and voltage. Used for inspecting the waveform of each sensor.

FU(H4SO)-13

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Throttle Body FUEL INJECTION (FUEL SYSTEMS)

2. Throttle Body

C: INSPECTION

A: REMOVAL

1. THROTTLE SENSOR (METHOD WITH CIRCUIT TESTER)

1) Disconnect the ground cable from battery.

1) Remove the glove box lid assembly, glove box lower cover, instrument panel side cover LH and glove box back panel. 2) Turn the ignition switch to ON. (engine OFF) 3) Measure the voltage between ECM connector terminals.

IG-02107

2) Remove the air intake boot assembly. 3) Disconnect the throttle position sensor connector (A). 4) Remove the bolts (B) which secure the throttle body to the multi-function duct assembly, and remove the throttle body.

FU-04956 (A)

(B)

7 6 5 4 3 17 16 15 14 13 12 11 27 26 25 24 23 22 21 34 33 32 31

(B)

2 1 10 9 8 20 19 18 30 29 28

(A)

V FU-04049

FU-06490

B: INSTALLATION

(A) To ECM connector

Install in the reverse order of removal. NOTE: Use a new gasket.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

Throttle sensor

Main

Sub

Accelerator pedal Not depressed (Full closed)

Terminal No.

Standard Approx. 0.6 V

18 (+) and 29 (–)

Depressed Approx. 3.96 V (Full opened) Not depressed Approx. 1.48 V (Full closed) 28 (+) and 29 (–) Depressed Approx. 4.17 V (Full opened)

4) After inspection, install the related parts in the reverse order of removal.

FU(H4SO)-14

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Throttle Body FUEL INJECTION (FUEL SYSTEMS)

2. THROTTLE SENSOR (METHOD WITH SUBARU SELECT MONITOR) 1) Turn the ignition switch to ON. (engine OFF) 2) Read the throttle opening angle signal and voltage of throttle sensor using Subaru Select Monitor.

Throttle sensor Main Sub

Throttle opening angle signal 0.0 % 100.0 %

Approx. 0.6 V Approx. 3.96 V

0.0 % 100.0 %

Approx. 1.48 V Approx. 4.17 V

Standard

3. OTHER INSPECTIONS 1) Check that the throttle body has no deformation, cracks or other damages. 2) Check that the engine coolant hose has no cracks, damage or loose part.

FU(H4SO)-15

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

3. Intake Manifold

9) Disconnect the fuel delivery pipe (B) from fuel gallery RH.

A: REMOVAL 1. INTAKE MANIFOLD

(B)

1) Release the fuel pressure. 2) Disconnect the ground cable from battery.

(A)

(A)

FU-05097

10) Disconnect the fuel delivery hose (A) and evaporation hose (B).

IG-02107

3) Open the fuel filler lid and remove the fuel filler cap. 4) Remove the air intake boot assembly. 5) Disconnect the connector (A) from the ignition coil of #3 cylinder. 6) Disconnect the PCV hose (B) from the rocker cover RH.

CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. (1) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose (A). ST 42099AE000 QUICK CONNECTOR RELEASE (2) Remove the clip and disconnect the evaporation hose (B) from the pipe. (A)

(A)

(B)

ST

(B) FU-04950

FU-04845

7) Remove the intake manifold protector RH.

11) Remove the generator cable clip (A) from the intake manifold protector LH. 12) Remove the oil filler pipe (B) from the rocker cover LH. 13) Disconnect the brake booster vacuum hose (C). (C) (A)

FU-04846

8) Disconnect the fuel injector connectors (A). (B) FU-05098

FU(H4SO)-16

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

14) Disconnect the connector (A) from the ignition coil of #2 cylinder. 15) Disconnect the PCV hose (B) from the rocker cover LH.

20) Remove the bolt (A) on RH side securing multifunction duct assembly to the intake manifold.

(A)

FU-05101

(B)

(A)

FU-04850

16) Remove the intake manifold protector LH.

21) Remove the intake manifold from cylinder head. 22) Remove the fuel gallery RH and fuel injector from the intake manifold.

FU-05099

17) Disconnect the fuel injector connectors (A) and disconnect the fuel delivery pipe (B) from fuel gallery LH.

FU-04860

23) Remove the fuel gallery LH, fuel pipe and fuel injector from the intake manifold.

(B)

(A)

(A)

FU-05100

18) Remove the clip (A) which holds the engine harness to intake manifold. 19) Remove the bolts (B) on the LH side which secure the multi-function duct assembly to intake manifold.

FU-05102

2. MULTI-FUNCTION DUCT ASSEMBLY 1) Release the fuel pressure. 2) Disconnect the ground cable from battery.

(A) (B)

FU-04853

FU(H4SO)-17

IG-02107

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

3) Open the fuel filler lid and remove the fuel filler cap. 4) Lift up the vehicle. 5) Remove the under cover. 6) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp qt) of engine coolant. 7) Lower the vehicle. 8) Remove the intake manifold. 9) Remove the bolt, and disconnect the bulkhead harness connector from the engine harness connector and rear engine hanger.

12) Disconnect the water hose (A) and EGR pipe (B) from the LH side of multi-function duct assembly. (A)

(B)

FU-04855

13) Disconnect the PCV hose (A) and water hose (B) from the RH side of multi-function duct assembly.

(A) (B)

FU-04880

FU-03924

10) Slide the engine harness connector in the direction of the arrow and remove it from the rear engine hanger.

14) Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).

(A) (B) (C)

FU-04962

FU-03925

11) Disconnect the connector from knock sensor.

15) Disconnect the connectors from front oxygen (A/F) sensor (A) and rear oxygen sensor (B). 16) Disconnect the connector (C) from the ignition coil of #1 cylinder. 17) Disconnect the connectors from oil switching solenoid valve RH (D), oil temperature sensor RH (E) and variable valve lift diagnosis switch (F), and remove the bolt to detach the ground terminal (G).

FU-05458

FU(H4SO)-18

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

23) Remove the clips (B) and remove the engine harness from the PCV pipe. (G) (E)

(A)

(F)

(A) (A)

(D)

(C)

(B) FU-05103

18) Slide the front oxygen (A/F) sensor connector and rear oxygen sensor connector in the direction of the arrow and remove them from the bracket.

(B) FU-04881

B: INSTALLATION 1. INTAKE MANIFOLD 1) Install in the reverse order of removal.

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 19 N·m (0.9 kgf-m, 14.0 ft-lb) T1 FU-04857

19) Disconnect the connector from the ignition coil of #4 cylinder. 20) Disconnect the connectors from the oil switching solenoid valve LH (A) and camshaft position sensor LH (B).

T2

T2

FU-05104

(A)

(B) T2

FU-04858

21) Remove the PCV pipe, multi-function duct assembly and engine harness as a single unit from the engine.

T2

FU-04884

NOTE: Use a new gasket.

FU-04859

22) Remove the bolts (A) and remove the multifunction duct assembly from the PCV pipe.

FU(H4SO)-19

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-05107 FU-04927

2. MULTI-FUNCTION DUCT ASSEMBLY 1) Install in the reverse order of removal. NOTE: Use a new gasket.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-05106

NOTE: Use a new gasket.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

FU-04931

FU-04846 FU-04932

FU-05099

NOTE: Use a new gasket.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-04933

C: INSPECTION 1) Check that the intake manifold and fuel pipe have no deformation, cracks and other damages. 2) Check that the hose has no cracks, damage or loose part.

FU(H4SO)-20

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Engine Coolant Temperature Sensor FUEL INJECTION (FUEL SYSTEMS)

4. Engine Coolant Temperature Sensor A: REMOVAL 1) Disconnect the ground cable from battery.

(A)

(B)

(C)

IG-02107

2) Remove the generator. 3) Drain engine coolant. 4) Disconnect the connector from the engine coolant temperature sensor, and remove the engine coolant temperature sensor.

FU-04053

(A) Thermometer (B) Engine coolant temperature sensor (C) Hexagonal part height: To approx.1/3

3) Raise water temperature gradually, measure the resistance between the engine coolant temperature sensor terminals when the temperature is 20°C (68°F) and 80°C (176°F). NOTE: Agitate the water for even temperature distribution. FU-04973

B: INSTALLATION

2 1

Install in the reverse order of removal. NOTE: Use a new gasket.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

EC-02428

C: INSPECTION 1) Check that the engine coolant temperature sensor has no deformation, cracks or other damages. 2) Immerse the engine coolant temperature sensor and a thermometer in water.

Water temperature

Terminal No.

Standard

20°C (68°F) 80°C (176°F)

1 and 2

2.45±0.2 kΩ 0.318±0.013 kΩ

CAUTION: Take care not to allow water to get into the engine coolant temperature sensor connector. Completely remove any water inside.

FU(H4SO)-21

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Crankshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

5. Crankshaft Position Sensor

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Disconnect the ground cable from battery.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

IG-02107

2) Remove the bolt which secures crankshaft position sensor to oil pump.

FU-04974

C: INSPECTION 1. CRANKSHAFT POSITION SENSOR (METHOD WITH CIRCUIT TESTER) 1) Measure the resistance between crankshaft position sensor terminals.

2 1 FU-04974

3) Remove the crankshaft position sensor, and disconnect the connector from the crankshaft position sensor. EC-02428

Terminal No. 1 and 2

Standard 2.04±0.204 kΩ

2. CRANKSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE) FU-04975

1) Prepare an oscilloscope. 2) Remove the glove box lid assembly, glove box lower cover, instrument panel side cover LH and glove box back panel.

FU(H4SO)-22

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Crankshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

3) Connect the probe to ECM connector.

FU-04956 (A)

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26

FU-04758

(A) To ECM connector Terminal No. 17 25

Probe + –

4) Start the engine and let it idle. 5) Check that the pattern is the same as the waveform and voltage shown below. 10ms 5V

0

(A)

FU-04057

(A) One crankshaft rotation

6) After inspection, install the related parts in the reverse order of removal.

3. OTHER INSPECTIONS Check that the crankshaft position sensor has no deformation, cracks or other damages.

FU(H4SO)-23

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Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

6. Camshaft Position Sensor A: REMOVAL

6) Remove the camshaft position sensor from the camshaft position sensor support.

1) Disconnect the ground cable from battery.

FU-00179

IG-02107

2) Disconnect the connector from camshaft position sensor.

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: Camshaft position sensor support 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) Camshaft position sensor 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-04890

3) Remove the bolt which secures camshaft position sensor to camshaft position sensor support.

FU-02724

4) Remove the bolt which secures camshaft position sensor support to camshaft cap LH.

FU-02725

5) Remove the camshaft position sensor and the camshaft position sensor support as a unit.

FU(H4SO)-24

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Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

C: INSPECTION

2. OTHER INSPECTIONS

1. CAMSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE)

Check that the camshaft position sensor has no deformation, cracks or other damages.

1) Prepare an oscilloscope. 2) Remove the glove box lid assembly, glove box lower cover, instrument panel side cover LH and glove box back panel. 3) Connect the probe to ECM connector.

FU-04956 (A)

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 21 22 21 20 19 18 31 30 29 28 27 26

FU-04346

(A) To ECM connector Terminal No. 12 22

Probe + –

4) Start the engine and let it idle. 5) Check that the pattern is the same as the waveform and voltage shown below.

LH 0

(A) RH 0

(A)

5V 40ms

FU-04209

(A) One camshaft rotation

6) After inspection, install the related parts in the reverse order of removal.

FU(H4SO)-25

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Knock Sensor FUEL INJECTION (FUEL SYSTEMS)

7. Knock Sensor

B: INSTALLATION

A: REMOVAL

1) Install the knock sensor to the cylinder block.

1) Disconnect the ground cable from battery.

NOTE: The portion of the knock sensor cord that is pulled out must be positioned at a 60° angle relative to the engine rear.

Tightening torque: 24 N·m (2.4 kgf-m, 17.7 ft-lb) (A)

IG-02107

2) Remove the air intake boot assembly. 3) Disconnect the knock sensor connector.

60 FU-02727

(A) Front side of vehicle

2) Connect the knock sensor connector.

FU-04698

4) Remove the knock sensor from cylinder block.

FU-04698

3) Install the air intake boot assembly. 4) Connect the ground cable to battery.

FU-02726

IG-02107

FU(H4SO)-26

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Knock Sensor FUEL INJECTION (FUEL SYSTEMS)

C: INSPECTION 1) Check that the knock sensor has no deformation, cracks or other damages. 2) Measure the resistance between knock sensor terminals.

2 1

EC-02426

Terminal No. 1 and 2

Standard 560±28 kΩ

FU(H4SO)-27

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Throttle Position Sensor FUEL INJECTION (FUEL SYSTEMS)

8. Throttle Position Sensor A: SPECIFICATION Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to “Throttle Body” for removal and installation procedure.

FU(H4SO)-28

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Mass Air Flow and Intake Air Temperature Sensor FUEL INJECTION (FUEL SYSTEMS)

9. Mass Air Flow and Intake Air Temperature Sensor

2) Check that the voltage changes when air is blown to the mass air flow sensor unit from arrow direction.

A: REMOVAL 1) Disconnect the ground cable from battery.

FU-04063

IG-02107

2) Disconnect the connector from the mass air flow and intake air temperature sensor, and remove the mass air flow and intake air temperature sensor.

2. CHECK INTAKE AIR TEMPERATURE SENSOR UNIT Measure the resistance between intake air temperature sensor terminals.

5 4 3 2 1

FU-04064 FU-04699

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 1 N·m (0.1 kgf-m, 0.7 ft-lb)

Temperature –20°C (–4°F) 20°C (68°F) 60°C (140°F)

Terminal No. 1 and 2

Standard 16.0±2.4 kΩ 2.45±0.24 kΩ 0.58±0.087 kΩ

3. OTHER INSPECTIONS

C: INSPECTION 1. CHECK MASS AIR FLOW SENSOR UNIT 1) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, circuit tester positive terminal to terminal No. 5 and the circuit tester negative terminal to terminal No. 4.

1) Check that the mass air flow and intake air temperature sensor has no deformation, cracks or other damages. 2) Check that the mass air flow and intake air temperature sensor has no dirt.

5 4 3 2 1

V FU-04062

FU(H4SO)-29

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Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS)

10.Manifold Absolute Pressure Sensor

3 2 1

A: REMOVAL 1) Disconnect the ground cable from battery.

V

IG-02107

2) Remove the air intake boot assembly. 3) Disconnect the connector from the manifold absolute pressure sensor and remove the manifold absolute pressure sensor from throttle body.

1.5V

1.5V 4.8

1.5V

5.2V FU-04491

3) Connect the Mighty Vac to the pressure port (A) of manifold absolute pressure sensor.

FU-04700

B: INSTALLATION

(A) FU-04492

Install in the reverse order of removal.

4) Check the voltage when generating vacuum and positive pressure using Mighty Vac.

NOTE: Use new O-rings.

CAUTION: Do not apply vacuum of less than –88 kPa (–0.9 kgf/cm2, –12.8 psi). Doing so may damage the manifold absolute pressure sensor.

Tightening torque: 2 N·m (0.2 kgf-m, 1.5 ft-lb)

C: INSPECTION 1) Check that the manifold absolute pressure sensor has no deformation, cracks or other damages. 2) Connect dry-cell battery positive terminal to terminal No. 3 and dry-cell battery ground terminal to terminal No. 2, circuit tester negative terminal to terminal No. 2 and the circuit tester positive terminal to terminal No. 1. NOTE: • Use new dry-cell batteries. • Using circuit tester, check the voltage of a single dry-cell battery is 1.6 V or more. And also check the voltage of three batteries in series is between 4.8 V and 5.2 V.

NOTE: When vacuum occurs at the pressure port of manifold absolute pressure sensor, the voltage will drop from the value as in step 3). When positive pressure occurs, on the other hand, the voltage will rise. Pressure –88 kPa (–0.9 kgf/cm2, –12.8 psi) –35 kPa (–0.4 kgf/cm2, –5.1 psi) 19 kPa (–0.2 kgf/cm2, 2.8 psi)

FU(H4SO)-30

Terminal No.

Standard

2 (+) and 1 (–)

Approx. 1 V (when 25°C (77°F)) Approx. 2.6 V (when 25°C (77°F)) Approx. 4.2 V (when 25°C (77°F))

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EGR Valve FUEL INJECTION (FUEL SYSTEMS)

11.EGR Valve

C: INSPECTION

A: REMOVAL

1) Check that the EGR valve has no deformation, cracks or other damages. 2) Measure the resistance between EGR valve terminals.

1) Disconnect the ground cable from battery.

3 2 1 6 5 4

IG-02107

2) Remove the multi-function duct assembly. 3) Remove the EGR valve from the multi-function duct assembly.

FU-04701

B: INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU(H4SO)-31

FU-04101

Terminal No. 2 and 1 2 and 3 5 and 4 5 and 6

Standard 22±2 Ω 22±2 Ω 22±2 Ω 22±2 Ω

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Fuel Injector FUEL INJECTION (FUEL SYSTEMS)

12.Fuel Injector

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Release the fuel pressure. 2) Disconnect the ground cable from battery.

NOTE: Use new O-rings.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

IG-02107

3) Open the fuel filler lid and remove the fuel filler cap. 4) Remove the intake manifold. 5) Remove the bolts securing the fuel gallery to intake manifold.

FU-04860

C: INSPECTION 1) Check that the fuel injector has no deformation, cracks or other damages. 2) Measure the resistance between fuel injector terminals.

2 1

EC-02428 FU-04860

6) Remove the fuel injector while lifting up the fuel gallery.

FU-05133

FU(H4SO)-32

Terminal No.

Standard

1 and 2

Approx. 12.0 Ω (when 20°C (68°F))

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Variable Valve Lift Diagnosis Oil Pressure Switch FUEL INJECTION (FUEL SYSTEMS)

13.Variable Valve Lift Diagnosis Oil Pressure Switch A: REMOVAL 1) Disconnect the ground cable from battery.

IG-02107

2) Remove the air intake boot assembly. 3) Disconnect the connector from the variable valve lift diagnosis oil pressure switch. 4) Remove the variable valve lift diagnosis oil pressure switch.

FU-05108

B: INSTALLATION Install in the reverse order of removal. NOTE: Apply liquid gasket to the variable valve lift diagnosis oil pressure switch threads.

Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 17 N·m (1.7 kgf-m, 12.5 ft-lb)

C: INSPECTION 1) Check that the variable valve lift diagnosis oil pressure switch does not have deformation, cracks or damage. 2) Check the variable valve lift diagnosis oil pressure switch installation portion for oil leakage and oil seepage.

FU(H4SO)-33

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Oil Temperature Sensor FUEL INJECTION (FUEL SYSTEMS)

14.Oil Temperature Sensor

C: INSPECTION

A: REMOVAL

1) Check that the oil temperature sensor has no deformation, cracks or other damages. 2) Measure the resistance between oil temperature sensor terminals.

1) Disconnect the ground cable from battery.

2 1

IG-02107

2) Remove the air intake boot assembly. 3) Disconnect the connector from oil temperature sensor. 4) Remove the oil temperature sensor.

FU-04888

B: INSTALLATION Install in the reverse order of removal. NOTE: Apply liquid gasket to the oil temperature sensor threads.

Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

FU-04888

FU(H4SO)-34

EC-02428

Terminal No. 1 and 2

Standard 2.45±0.2 (when 20°C (68°F))

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Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS)

15.Front Oxygen (A/F) Sensor

B: INSTALLATION

A: REMOVAL

CAUTION: If lubricant is spilt over the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier.

1) Disconnect the ground cable from battery.

CAUTION: Never apply anti-seize compound to the protector of front oxygen (A/F) sensor. IG-02107

2) Remove the air intake duct. 3) Remove the clip (C) fastening the harness and disconnect the front oxygen (A/F) sensor connector (A).

(B)

Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the front oxygen (A/F) sensor. Tightening torque: 21 N·m (2.1 kgf-m, 15.5 ft-lb)

(B) (A)

(A) (C)

FU-02735

FU-04697

4) Lift up the vehicle. 5) Remove the under cover. 6) Apply spray-type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. 7) Remove the front oxygen (A/F) sensor. CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.

(A) Front oxygen (A/F) sensor (B) Rear oxygen sensor

3) Install the under cover. 4) Lower the vehicle. 5) Connect the front oxygen (A/F) sensor connector (A) and fasten the harness with clips (C).

(B) (A)

(B)

(C)

FU-04697

6) Install the air intake duct.

(A) FU-02735

(A) Front oxygen (A/F) sensor (B) Rear oxygen sensor

FU(H4SO)-35

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Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS)

7) Connect the ground cable to battery.

IG-02107

C: INSPECTION 1) Check that the front oxygen (A/F) sensor has no deformation, cracks or other damages. 2) Measure the resistance between front oxygen (A/F) sensor terminals.

1 2 3 4

FU-04937

Terminal No.

Standard

3 and 4

2.4+0.5 –0.24 Ω (when 20°C (68°F))

FU(H4SO)-36

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Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS)

16.Rear Oxygen Sensor

B: INSTALLATION

A: REMOVAL

CAUTION: If lubricant is spilt over the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing rear oxygen sensor, apply the anti-seize compound only to the threaded portion of rear oxygen sensor to make the next removal easier.

1) Disconnect the ground cable from battery.

CAUTION: Never apply anti-seize compound to the protector of rear oxygen sensor. IG-02107

2) Remove the air intake duct. 3) Remove the clips (C) fastening the harness and disconnect the rear oxygen sensor connector (B).

Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the rear oxygen sensor. Tightening torque: 21 N·m (2.1 kgf-m, 15.5 ft-lb)

(B) (A)

(C)

(B)

(A)

FU-04697

4) Lift up the vehicle. 5) Remove the under cover. 6) Apply spray-type lubricant to the threaded portion of rear oxygen sensor, and leave it for one minute or more. 7) Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.

FU-02735

(A) Front oxygen (A/F) sensor (B) Rear oxygen sensor

3) Install the under cover. 4) Lower the vehicle. 5) Connect the rear oxygen sensor connector (B) and fasten the harness with clips (C).

(B) (A) (B)

(C) (A) FU-02735

FU-04697

6) Install the air intake duct.

(A) Front oxygen (A/F) sensor (B) Rear oxygen sensor

FU(H4SO)-37

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Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS)

7) Connect the ground cable to battery.

IG-02107

C: INSPECTION 1) Check that the rear oxygen sensor has no deformation, cracks or other damages. 2) Measure the resistance between rear oxygen sensor terminals.

2 1 4 3

FU-04073

Terminal No.

Standard

1 and 2

5.6+0.8 –0.6 Ω (when 20°C (68°F))

FU(H4SO)-38

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Engine Control Module (ECM) FUEL INJECTION (FUEL SYSTEMS)

17.Engine Control Module (ECM)

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Disconnect the ground cable from battery.

IG-02107

2) Remove the glove box lid assembly, glove box lower cover, instrument panel side cover LH and glove box back panel. 3) Remove the connectors from ECM.

CAUTION: • When the ECM of model with immobilizer has been replaced, be sure to perform the registration of immobilizer system. (Refer to “PC application help for Subaru Select Monitor”.) • If replacing ECM or the bracket, replace both parts with new parts at a time. • After installing the bracket to ECM, do not separate the bracket. • If the bracket has been installed to ECM in the wrong direction, replace both parts to new parts. NOTE: When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system.

C: INSPECTION Check that the ECM has no deformation, cracks or other damages.

FU-04984

4) Remove the ECM from vehicle.

FU-04985

FU(H4SO)-39

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Main Relay FUEL INJECTION (FUEL SYSTEMS)

18.Main Relay

C: INSPECTION

A: REMOVAL

1) Check that the main relay has no deformation, cracks or other damages. 2) Measure the resistance between main relay terminals.

1) Disconnect the ground cable from battery.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

IG-02107

2) Remove the glove box lid assembly, glove box lower cover, instrument panel side cover LH and glove box back panel. 3) Remove the main relay from the relay holder.

1 2 3 4

FU-04076

FU-04986

B: INSTALLATION Install in the reverse order of removal.

FU(H4SO)-40

Terminal No. 1 and 2

Standard 1 MΩ or more

3 and 4

130.4 — 230.8 Ω (When 20°C (68°F))

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Main Relay FUEL INJECTION (FUEL SYSTEMS)

3) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, and measure the resistance between the main relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2 3 4

FU-04077

Terminal No. 1 and 2

Standard Less than 1 Ω

FU(H4SO)-41

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Fuel Pump Relay FUEL INJECTION (FUEL SYSTEMS)

19.Fuel Pump Relay

C: INSPECTION

A: REMOVAL

1) Check that the fuel pump relay has no deformation, cracks or other damages. 2) Measure the resistance between fuel pump relay terminals.

1) Disconnect the ground cable from battery.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

IG-02107

2) Remove the glove box lid assembly, glove box lower cover, instrument panel side cover LH and glove box back panel. 3) Remove the fuel pump relay from the relay holder.

1 2 3 4

FU-04076

FU-04987

B: INSTALLATION Install in the reverse order of removal.

FU(H4SO)-42

Terminal No. 1 and 2

Standard 1 MΩ or more

3 and 4

93.8 — 136.4 Ω (When 20°C (68°F))

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Fuel Pump Relay FUEL INJECTION (FUEL SYSTEMS)

3) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, and measure the resistance between the fuel pump relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2 3 4

FU-04077

Terminal No. 1 and 2

Standard Less than 1 Ω

FU(H4SO)-43

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Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEMS)

20.Electronic Throttle Control Relay A: REMOVAL 1) Disconnect the ground cable from battery.

C: INSPECTION 1) Check that the electronic throttle control relay has no deformation, cracks or other damages. 2) Measure the resistance between electronic throttle control relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

IG-02107

2) Remove the glove box lid assembly, glove box lower cover, instrument panel side cover LH and glove box back panel. 3) Remove the electronic throttle control relay from the relay holder.

1 2 3 4

FU-04076

FU-04988

B: INSTALLATION Install in the reverse order of removal.

FU(H4SO)-44

Terminal No. 1 and 2

Standard 1 MΩ or more

3 and 4

93.8 — 136.4 Ω (When 20°C (68°F))

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Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEMS)

3) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, and measure the resistance between the electronic throttle control relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2 3 4

FU-04077

Terminal No. 1 and 2

Standard Less than 1 Ω

FU(H4SO)-45

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Fuel FUEL INJECTION (FUEL SYSTEMS)

21.Fuel

• Catch the fuel from hoses using a container or cloth.

A: PROCEDURE 1. RELEASING OF FUEL PRESSURE WARNING: Place “NO OPEN FLAMES” signs near the working area.

ST

CAUTION: Be careful not to spill fuel. 1) Remove the fuse of fuel pump from main fuse box.

FU-04949

3) Connect ST to the fuel delivery hose. ST 18471AA000 FUEL PIPE ADAPTER 4) Drive the fuel pump and drain the fuel using Subaru Select Monitor. (Refer to “PC application help for Subaru Select Monitor”.) CAUTION: Be careful not to spill fuel. 5) Install the related parts in the reverse order after draining the fuel. FU-04800

2) Start the engine and run it until it stalls. 3) After the engine stalls, crank it for five more seconds. 4) Turn the ignition switch to OFF. 5) Install the fuse of fuel pump to the main fuse box.

2. DRAINING FUEL (WITH SUBARU SELECT MONITOR) WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. NOTE: • If the fuel pump cannot be driven, refer to the procedures for draining from the fuel filler hose.

• Be careful not to let the battery run-out. 1) Release the fuel pressure. 2) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE

3. DRAINING FUEL (THROUGH THE FUEL FILLER HOSE) WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Be careful not to spill fuel. • Fuel may remain in the fuel filler pipe. Draining the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose (ø10 or less) before the operation. 1) Lift up the vehicle. 2) Remove the rear exhaust pipe and muffler. 3) Open the fuel filler lid and remove the fuel filler cap. 4) Drain the fuel from the fuel filler pipe through the filler opening using the gasoline proof pump and the gasoline proof hose (ø10 or less). 5) Disconnect the fuel filler hoses from the fuel filler pipe. CAUTION: • Be careful not to spill fuel.

CAUTION: • Be careful not to spill fuel.

FU(H4SO)-46

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Fuel FUEL INJECTION (FUEL SYSTEMS)

• Catch the fuel from hoses using a container or cloth.

FU-04803

6) Set the container under the vehicle and insert the gasoline proof hose (ø10 or less) into the fuel filler hose to drain the fuel. CAUTION: Be careful not to spill fuel. 7) Install the related parts in the reverse order after draining the fuel.

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb)

FU(H4SO)-47

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

22.Fuel Tank

(3) Push the grommet (D) down and remove the service hole cover.

A: REMOVAL

(C)

WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery.

(D)

(B) (C) (A)

FU-04991

7) Remove the service hole cover of fuel sub level sensor.

FU-05070 IG-02107

4) Remove the rear seat cushion. 5) Remove the clips (A) and seat cushion hooks (B), and turn over the floor mat (C).

8) Disconnect the quick connector on the fuel delivery tube (A). (A)

(C) FU-05069 (B)

(A)

(A)

(B) FU-04990

6) Remove the service hole cover of fuel pump. (1) Disconnect the fuel cord connector (A), and remove the clip (B). (2) Remove the screw (C).

9) Remove the rear wheels. 10) Lift up the vehicle. 11) Remove the rear ABS wheel speed sensor from the rear housing.

FU-04994

FU(H4SO)-48

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

12) Remove the rear ABS wheel speed sensor harness bracket from the upper arm.

17) Remove the heat shield cover.

(A) DS-00472 FU-04087

13) Remove the rear brake hose bracket from rear housing.

(A) Heat shield cover

18) Remove the propeller shaft. 19) Remove the clip (A) securing the fuel tank protector and heat shield cover. 20) Remove the bolts (B) and nuts (C) securing the fuel tank protector, and remove the fuel tank protector. (B)

FU-04995

(B)

(B) (C)

(C)

14) Remove the rear disc brake assembly and tie it to the body side of the vehicle.

(A)

FU-04997

21) Remove the bolts and nuts securing the heat shield cover and remove the heat shield cover.

FU-04998

22) Remove the rear suspension assembly.

FU-04996

15) Remove the parking brake cable from parking brake assembly. 16) Remove the rear exhaust pipe and muffler.

WARNING: A helper is required to perform this work. (1) Support the rear differential with the transmission jack.

FU(H4SO)-49

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

(2) Remove the bolt and nut which secure rear shock absorber to rear suspension arm.

NOTE: Disconnect the quick connector as shown in the figure. 1 2

FU-03359 1

(3) Remove the bolts which secure the rear suspension assembly to the body.

FU-05002

FU-05003 FU-04999

(4) Remove the rear suspension assembly. 23) Disconnect the air vent hose from the fuel tank.

25) Disconnect the fuel filler hose (A) and circulate hose (B) from the fuel filler pipe assembly. (B)

(A)

FU-05149 FU-05083

24) Disconnect the quick connector of the circulate tube from evaporation pipe.

26) Support the fuel tank with a transmission jack, remove the bolts from the fuel tank band, and remove the fuel tank from the vehicle. WARNING: • A helper is required to perform this work.

FU(H4SO)-50

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

• Fuel may remain in the fuel tank. This will cause the left and right sides to be unbalanced. Be careful not to drop the fuel tank when removing.

(1)

(2)

(3)

(4)

L/2 L

FU-04500

(1) (2) (3) (4)

FU-05004

B: INSTALLATION 1) Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band. WARNING: A helper is required to perform this work.

Hose Clamp or clip Spool Pipe

3) Connect the quick connector of the circulate tube to the evaporation pipe as shown in the figure. CAUTION: • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe. • Make sure that the quick connector is securely connected.

FU-05004

2) Securely insert the fuel filler hose (A) and circulate hose (B) to the spool, then attach the clamp or clip as shown in the figure.

FU-05036

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb) (B)

FU-05003

(A)

FU-05149

FU(H4SO)-51

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

4) Connect the air vent hose to fuel tank.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb)

FU-05083 FU-03359

5) Tighten the bolts of the fuel tank band in the order shown in the figure.

7) Install the heat shield cover.

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

1

2

4

3

FU-05005

6) Install the rear suspension assembly. WARNING: A helper is required to perform this work. (1) Support the rear differential with the transmission jack. (2) While supporting the rear suspension assembly, install the rear suspension assembly to the body.

Tightening torque: T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb) T2: 200 N·m (20.4 kgf-m, 147.5 ft-lb)

FU-04998

8) Install the bolts (B) and nuts (C) securing the fuel tank protector and install the clip (A) securing the fuel tank protector and heat shield cover.

Tightening torque: Nut (C): 9 N·m (0.9 kgf-m, 6.6 ft-lb) Bolt (B): 18 N·m (1.8 kgf-m, 13.3 ft-lb) (B)

(B)

(B) (C)

(C) (A)

T2

T2 FU-04997

T1

T1 FU-05006

(3) Install the rear shock absorber to the rear suspension arm. NOTE: Use a new self-locking nut.

9) Install the propeller shaft. 10) Install the rear exhaust pipe and muffler. 11) Lower the vehicle. 12) Connect the parking brake cable to the parking brake assembly. 13) Install the rear disc brake assembly.

FU(H4SO)-52

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 66 N·m (6.7 kgf-m, 48.7 ft-lb)

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

FU-04546

14) Install the rear brake hose bracket to the rear housing.

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

FU-04994

17) Install the rear wheels.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb) 18) Connect the quick connector of the fuel delivery tube (A). (A)

FU-04995

15) Install the rear ABS wheel speed sensor harness bracket to the upper arm.

FU-05069

19) Install the service hole cover of fuel sub level sensor.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

FU-04087

16) Install the rear ABS wheel speed sensor to the rear housing.

FU(H4SO)-53

FU-05070

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

20) Install the service hole cover of the fuel pump, and install the connector and clip. (C)

(D)

(B) (C) (A)

(A) (B) (C) (D)

FU-04991

Connector Clip Screw Grommet

21) Set the floor mat (C), and install clips (A) and seat cushion hooks (B).

(C)

(B)

(A)

(A)

(B) FU-04990

22) Install the rear seat cushion. 23) Connect the ground cable to battery.

IG-02107

24) Inspect the wheel alignment and adjust if necessary.

C: INSPECTION 1) Check that the fuel tank and fuel pipe have no deformation, cracks and other damages. 2) Check that the fuel hose has no cracks, damage or loose part.

FU(H4SO)-54

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Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS)

23.Fuel Filler Pipe

10) Disconnect the fuel filler hose (A) and circulate hose (B) from the fuel filler pipe assembly.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery.

(B)

(A)

FU-05149

11) Disconnect the evaporation hose (A) from fuel filler pipe assembly and remove the bolts and nuts securing the fuel filler pipe assembly to the vehicle body.

(A)

IG-02107

4) Open the fuel filler lid, and remove the filler cap. 5) Turn the fuel filler pipe protector in the direction of the arrow to unlock and remove it.

FU-05150 FU-04044

6) Remove the rear wheel RH. 7) Lift up the vehicle. 8) Remove the rear mud guard RH. 9) Remove the rear sub frame.

12) Remove the fuel filler pipe assembly from the underside of the vehicle.

FU(H4SO)-55

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Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 1) Open the fuel filler lid. 2) Insert the fuel filler pipe assembly into the rubber saucer from inside of the rear fender. 3) Install the fuel filler pipe assembly to the vehicle body and connect the evaporation hose (A) and circulate hose (B) to the fuel filler pipe assembly.

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb) (B)

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(A)

FU-05149 (A) (1)

(2)

(3)

(4)

L/2 L

FU-04500

(1) (2) (3) (4)

FU-05150

4) Align the cutout on the fuel filler pipe protector and the protrusion of the neck holder and insert them all the way, and then turn the fuel filler pipe protector in the direction of the arrow until it is locked.

Hose Clamp or clip Spool Pipe

6) Install the rear sub frame. 7) Install the rear mud guard RH. 8) Lower the vehicle. 9) Install the rear wheel RH.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb) 10) Connect the ground cable to battery.

FU-04104

5) Securely insert the fuel filler hose (A) and circulate hose (B) to the spool, then attach the clamp or clip as shown in the figure.

IG-02107

11) Inspect the wheel alignment and adjust if necessary.

FU(H4SO)-56

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Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS)

C: DISASSEMBLY

E: INSPECTION

Remove the fuel filler pipe bracket from the fuel filler pipe.

Check that the fuel filler pipe does not have deformation, cracks or other damages.

FU-05009

D: ASSEMBLY Install the fuel filler pipe bracket to the fuel filler pipe.

Tightening torque: 7.35 N·m (0.7 kgf-m, 5.4 ft-lb)

FU-05009

FU(H4SO)-57

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Fuel Pump FUEL INJECTION (FUEL SYSTEMS)

24.Fuel Pump

(3) Push the grommet (D) down and remove the service hole cover.

A: REMOVAL

(C)

WARNING: Place “NO OPEN FLAMES” signs near the working area.

(D)

CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: Fuel pump assembly consists of fuel pump, fuel filter, fuel chamber and fuel level sensor. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery.

(B) (C) (A)

FU-04991

7) Disconnect the connector (A) from fuel pump, and remove the clip (B) securing the harness. 8) Disconnect the quick connector of fuel delivery tube (C) and fuel sub delivery tube (D).

(D) (C) (A)

(B)

FU-05063

9) Remove the nuts securing the fuel pump upper plate to the fuel tank and remove the fuel pump upper plate. IG-02107

4) Remove the rear seat cushion. 5) Remove the clips (A) and seat cushion hooks (B), and turn over the floor mat (C).

FU-04534

10) Remove the fuel pump assembly from the fuel tank.

(C)

(B)

(A)

(A)

(B) FU-04990

6) Remove the service hole cover. (1) Disconnect the fuel cord connector (A), and remove the clip (B). (2) Remove the screw (C).

FU(H4SO)-58

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Fuel Pump FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION Install in the reverse order of removal while being careful of the following. • Make sure the sealing portion is free from fuel or foreign matter before installation. • Align protrusion (A) of the gasket to the position shown in the figure. • Insert the protrusion (B) of gasket to the fuel pump upper plate. (3 places) • Align the protrusion (C) of fuel pump assembly with the cutout on the fuel pump upper plate. • Tighten the nuts to the specified torque in the order as shown in the figure. NOTE: Use a new gasket and retainer.

Tightening torque: 4.4 N·m (0.4 kgf-m, 3.2 ft-lb) 2

(C)

4

7

(B)

(B) 5

6

(a)

3

8 (B)

1

(A)

FU-05064

(a) Front side of vehicle

C: INSPECTION 1) Check that the fuel pump has no deformation, cracks or other damages. 2) Connect battery positive terminal to terminal No. 5 and battery ground terminal to terminal No. 6, and inspect the fuel pump operation. WARNING: • Wipe off fuel completely. • Keep the battery as far apart from fuel pump as possible. • Do not run the fuel pump for a long time under non-load condition. 2 1 4 3 6 5

FU-04110

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Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS)

25.Fuel Level Sensor

4) Press two claws (A) of the fuel level sensor, and slide the fuel level sensor in the direction of the arrow to remove the fuel level sensor.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area.

(A)

(A)

CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: The fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly. 2) Disconnect the connector from the fuel filter assembly.

FU-05015

B: INSTALLATION Install in the reverse order of removal.

C: INSPECTION 1) Check that the fuel level sensor has no damage. 2) Measure the fuel level sensor float position. NOTE: When inspecting the fuel level sensor, perform the work with the sensor installed to the fuel pump. • Model with fuel level sensor bent in 3 locations

(1) FU-05065

3) Remove the harness from the hooks (A) on the fuel chamber assembly and remove the fuel temperature sensor (B) from fuel chamber assembly.

(A)

(3)

(B)

(2) (B)

FU-05067

(1) FULL (2) EMPTY (3) Fuel tank seating surface

(A)

FU-05066

Float position FULL to Fuel tank seating surface (A) EMPTY to Fuel tank seating surface (B)

FU(H4SO)-60

Standard 126.4±4 mm (4.976±0.157 in) 11.0±4 mm (0.433±0.157 in)

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Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS)

• Model with fuel level sensor bent in 2 locations

• Model with fuel level sensor bent in 2 locations

(1) (A) (A) (2) (3)

(B)

(B)

FU-08401

(1) FULL (2) EMPTY (3) Fuel tank seating surface Float position FULL to Fuel tank seating surface (A) EMPTY to Fuel tank seating surface (B)

2 1 4 3 6 5 Standard

120.9±4 mm (4.759±0.157 in) 14.8±4 mm (0.583±0.157 in)

3) Measure the resistance between fuel level sensor terminals. • Model with fuel level sensor bent in 3 locations

FU-08402

Float position FULL (A) EMPTY (B)

(A)

(B)

2 1 4 3 6 5

FU-05068

FU(H4SO)-61

Terminal No. 1 and 4

Standard 2.0±1.0 Ω 31.9±1.0 Ω

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Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS)

26.Fuel Sub Level Sensor

6) Disconnect the connector (A) from fuel sub level sensor, and remove the clip (B) securing the fuel cord from fuel sub level sensor protector.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery.

(B)

(A)

FU-05071

7) Remove the bolts (A) securing the fuel sub level sensor protector to the fuel sub level sensor upper plate, and remove the fuel sub level sensor protector. 8) Disconnect the quick connector on the fuel sub delivery tube (B). (A)

(B) IG-02107

4) Remove the rear seat cushion. 5) Remove the service hole cover.

FU-05072

9) Remove the nuts securing the fuel sub level sensor upper plate to the fuel tank and remove the fuel sub level sensor upper plate.

FU-05070 FU-04569

10) Remove the fuel sub level sensor from the fuel tank.

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Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION

C: INSPECTION

Install in the reverse order of removal while being careful of the following. • Make sure the sealing portion is free from fuel or foreign matter before installation. • Align protrusion (A) of the gasket to the position shown in the figure. • Align protrusion (B) of the fuel sub level sensor to the cutout in the fuel sub level sensor upper plate. • After tightening the bolts to the specified torque in the order indicated in the figure, install the fuel sub level sensor protector.

1) Check that the fuel sub level sensor has no damage. 2) Measure the fuel sub level sensor float position. (A)

(1) (3)

(B)

NOTE: Use a new gasket and retainer.

(2) FU-04213

Tightening torque: 4.4 N·m (0.4 kgf-m, 3.2 ft-lb)

(1) FULL (2) EMPTY (3) Datum points

4 2

Float position

6

FULL to Datum point (A) 5

EMPTY to Datum point (B) (a)

1

(B) 3 (A)

FU-04533

Standard 6.4±3.5 mm (0.252±0.138 in) 163.3±3.5 mm (6.429±0.138 in)

3) Measure the resistance between fuel sub level sensor terminals.

(a) Front side of vehicle (A)

(B)

FU-05073

2 1

FU-04214

Float position FULL (A) EMPTY (B)

FU(H4SO)-63

Terminal No. 1 and 2

Standard 2.0±1.0 Ω 62.1±1.0 Ω

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Fuel Filter FUEL INJECTION (FUEL SYSTEMS)

27.Fuel Filter

5) Remove the fuel pump holder from the fuel filter assembly.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. • Be careful not to drop or apply any impact to the fuel pump during work. This may deteriorate its performance.

FU-05023

6) Remove the fuel pump from the fuel filter assembly.

NOTE: The fuel filter is built in fuel pump assembly. 1) Remove the fuel pump assembly. 2) Remove the fuel level sensor and fuel temperature sensor. 3) Disconnect the connector from the fuel filter assembly.

FU-05074

4) Disengage the claw connecting the fuel filter assembly and fuel chamber assembly, and separate fuel filter assembly and fuel chamber assembly.

FU-05075

FU(H4SO)-64

FU-05024

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Fuel Filter FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 1) Assemble the gasket spacer (A) and support rubber cushion (B) to the fuel pump, and install the fuel pump to the fuel filter assembly.

• Check that the claw connecting the fuel filter assembly and fuel chamber assembly is securely fastened.

NOTE: • Use a new gasket spacer. • Use a new support rubber cushion. • Apply gasoline to the surface of gasket spacer and support rubber cushion.

(B)

(B)

(A) (A)

(A)

FU-03889

FU-05025

2) Install the fuel pump holder to the fuel filter assembly. FU-05075

4) Connect the fuel pump connector.

FU-03886

3) Install the pump module spring (A) to fuel filter assembly, and install the fuel chamber assembly (B). NOTE: • Use a new fuel chamber assembly.

FU-05074

5) Install the fuel level sensor and fuel temperature sensor. 6) Inspect the fuel level sensor. 7) Install the fuel pump assembly.

FU(H4SO)-65

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Fuel Delivery and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

28.Fuel Delivery and Evaporation Lines A: REMOVAL

FU-05093

WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. 3) Open the fuel filler lid and remove the fuel filler cap. 4) Remove the floor mat. 5) In the engine compartment, disconnect the fuel delivery hoses (A) and evaporation hose (B). CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth.

(1) Remove the connect check cover from the fuel delivery hose.

FU-05094

ST

(2) Install the ST to the fuel pipe. 42099AE000 QUICK CONNECTOR RELEASE (3) Disconnect the quick connector of the fuel delivery hose by pushing the ST in the direction of the arrow.

FU(H4SO)-66

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Fuel Delivery and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

(4) Remove the clip and disconnect the evaporation hose from the fuel pipe. (D) (C)

ST

(B)

(A)

(A)

FU-05081

(B) FU-05095

6) Remove the fuel tank. 7) Remove the rear mud guard LH. 8) Remove the purge hose (A), purge pipe (B), air vent hose (C) and drain tube assembly (D). NOTE: Disconnect the quick connector as shown in the figure.

9) Remove the fuel pipe assembly from vehicle. 10) Disconnect the quick connector, and disconnect the fuel delivery tube and fuel sub delivery tube. (1) Push the retainer in the direction of the arrow, disconnect the quick connector from pipe. NOTE: Clean the pipe and quick connector, if they are covered with dust.

1 2

(B) (A)

(C)

FU-00124 1

(A) Quick connector (B) Retainer (C) Pipe

(a) 1 2

(2) To prevent from damaging or entering foreign matter, wrap the pipes and quick connectors with plastic bag etc.

(b)

1

EC-02590

(a) Air vent hose (C), drain tube ASSY (D) (b) Purge pipe (B) FU-01333

11) Remove the evaporation pipe. (1) Remove the rear mud guard RH.

FU(H4SO)-67

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Fuel Delivery and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION

(2) Remove the evaporation hose.

Install in the reverse order of removal while being careful of the following.

1. INSTALLATION OF EVAPORATION PIPE 1) Install the evaporation pipe to the vehicle.

FU-05082

(3) Remove the trunk side trim panel assembly - side on RH. (4) Remove the evaporation pipe protector. FU-05033

2) Install the evaporation pipe protector.

Tightening torque: T1: 1 N·m (0.1 kgf-m, 0.7 ft-lb) T2: 7.5 N·m (0.7 kgf-m, 5.4 ft-lb) T2

FU-05032

(5) Remove the evaporation pipe from the vehicle.

T1

FU-05034

3) Install the trunk side trim panel assembly - side on RH. 4) Install the evaporation hose. FU-05033

FU-05082

5) Install the rear mud guard RH.

FU(H4SO)-68

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Fuel Delivery and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

2. CONNECTING THE FUEL LINE QUICK CONNECTOR

• Be sure to inspect tubes and their connections for any leakage of fuel.

CAUTION: Make sure there are no damage or dust on connections. If necessary, clean seal surface of pipe.

(A) (B)

(C) (A)

FU-00126

(B)

(A) Quick connector (B) Retainer (C) Pipe

FU-00125

3. EVAPORATION HOSE CONNECTION

(A) Seal surface (B) Pipe

Connect the evaporation hose to the pipe with an overlap of 15 to 20 mm (0.59 to 0.79 in).

1) Set the retainer to quick connector.

L = 17.5±2.5 mm (0.689±0.098 in)

NOTE: Use a new retainer. 2) Connect the quick connector to pipe.

(2)

(1)

(3)

CAUTION: • Make sure that the quick connector is securely connected. L/2 L FU-04501

(1) Hose (2) Clip (3) Pipe

(A)

(B)

(C) FU-00127

(A) Quick connector (B) Retainer (C) Pipe

• Make sure the two retainer pawls are engaged in their mating positions in the quick connector.

FU(H4SO)-69

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Fuel Delivery and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

4. CONNECTING THE EVAPORATION LINE QUICK CONNECTOR CAUTION: • Make sure there are no damage or dust on connections. If necessary, clean the seal surface of the pipe. • Make sure that the quick connector is securely connected. Connect the quick connector as shown in the figure.

C: INSPECTION 1) Check that the fuel pipe has no deformation, cracks or other damages. 2) Check that the hose and tube have no cracks, damage or loose part.

FU-05035

FU(H4SO)-70

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Fuel System Trouble in General FUEL INJECTION (FUEL SYSTEMS)

29.Fuel System Trouble in General A: INSPECTION Trouble

Insufficient fuel supply to injector

Possible cause a. Fuel pump does not operate. Defective terminal contact

Inspect contact, especially ground, and tighten it securely.

Trouble in electromagnetic or electronic circuit parts

Replace the faulty parts.

b. Decline of fuel pump function

Replace the fuel pump.

c. Clogged fuel filter

Replace the fuel filter. Clean or replace the fuel tank if necessary.

d. Clogged or bent pipe, hose or tube of fuel line

Clean, correct or replace the pipe, hose or tube of the fuel line.

e. Air is mixed in fuel system.

Leakage or run-out of fuel

Gasoline smell inside of compartment Defective fuel gauge Noise

Corrective action

f. Damaged diaphragm of pressure regulator a. Loose connection in pipe, hose or tube of fuel line b. Cracks in pipe, hose or tube of fuel line c. Defective welded part of fuel tank

Check the fuel line connections, and repair or replace the defective part. Replace the pressure regulator. Check the fuel line connections, and repair or replace the defective part. Replace the pipe, hose or tube of the fuel line. Replace the fuel tank.

d. Clogged or bent pipe, hose or tube of fuel line

Clean, correct or replace the pipe, hose or tube of the fuel line.

a. Loose connection in pipe, hose or tube of fuel line b. Improper installation of rubber saucer c. Defective canister

Check the fuel line connections, and repair or replace the defective part. Correct or replace the rubber saucer. Replace the canister.

a. Defective operation of fuel level sensor Replace the fuel level sensor. b. Defective operation of combination meter Replace the combination meter. a. Big operation noise or vibration from fuel pump Replace the fuel pump.

NOTE: • When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank. Fill fuel fully to prevent the problem. • In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop to 0°C (32°F) or less throughout the winter season, use a water removing agent in the fuel system to prevent freezing fuel system and accumulating water. • When water is accumulated in fuel filter, fill the water removing agent in the fuel tank. • Before using water removing agent, follow the cautions noted on the bottle.

FU(H4SO)-71

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Fuel System Trouble in General FUEL INJECTION (FUEL SYSTEMS)

FU(H4SO)-72

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EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(H4SO) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Page General Description ...................................................................................2 Front Catalytic Converter ...........................................................................3 Rear Catalytic Converter ............................................................................4 Canister ......................................................................................................5 Purge Control Solenoid Valve ....................................................................9 EGR Valve ...............................................................................................11 Fuel Level Sensor ....................................................................................12 Fuel Temperature Sensor ........................................................................13 Fuel Sub Level Sensor .............................................................................14 Fuel Tank Pressure Sensor .....................................................................15 Drain Filter ................................................................................................17 Drain Valve ...............................................................................................18 PCV Hose Assembly ................................................................................19 PCV Valve ................................................................................................20

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General Description EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

1. General Description A: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.

B: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 18353AA000

DESCRIPTION CLAMP PLIERS

REMARKS • Used for removing and installing the PCV hose. • This is a general tool made by the French company CAILLAU. (code) 54.0.000.205 To make this easier to obtain, it has been provided with a tool number.

ST18353AA000

2. GENERAL TOOL TOOL NAME Circuit tester Mighty Vac

REMARKS Used for measuring resistance and voltage. Used for inspection of the two-way valve.

EC(H4SO)-2

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Front Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

2. Front Catalytic Converter A: REMOVAL The front catalytic converter is integrated into the front exhaust pipe; therefore, refer to “Front Exhaust Pipe” for the removal procedure.

B: INSTALLATION The front catalytic converter is integrated into the front exhaust pipe; therefore, refer to “Front Exhaust Pipe” for the installation procedure.

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Check for hole or rust.

EC(H4SO)-3

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Rear Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

3. Rear Catalytic Converter A: REMOVAL The rear catalytic converter is integrated into the center exhaust pipe. Refer to “Center Exhaust Pipe” for removal procedures.

B: INSTALLATION The rear catalytic converter is integrated into the center exhaust pipe. Refer to “Center Exhaust Pipe” for installation procedures.

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Check for hole or rust.

EC(H4SO)-4

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

4. Canister

5) Remove the clip holding the rear wiring harness.

A: REMOVAL 1) Remove the rear wheel LH. 2) Lift up the vehicle. 3) Remove the rear mud guard LH. 4) Disconnect the quick connectors of the vent tube (A), canister drain tube (B) and charge tube (C), and remove the tubes from clips (D). NOTE: Disconnect the quick connector as shown in the figure.

EC-02608

6) Remove the canister from vehicle.

1 2

1 (a) 1 2

1

(b)

EC-02609 EC-02615

7) Disconnect the connector from drain valve.

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C)

(C) (A)

EC-02610 (B)

(D) EC-02607

8) Disconnect the vent tube (A), canister drain tube (B) and charge tube (C), and remove the canister drain tube (B) from clip (D).

EC(H4SO)-5

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

NOTE: Disconnect the quick connector as shown in the figure. 1

B: INSTALLATION 1) Install the vent tube (A), canister drain tube (B) and charge tube (C), and install the canister drain tube (B) to clip (D). CAUTION: • Make sure there are no damage or dust on connections. If necessary, clean the seal surface of the pipe. • Make sure that the quick connector is securely connected.

2

NOTE: Connect the quick connector as shown in the figure.

1 (a) 1 2

(b)

1

EC-02615 (a)

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C) (B)

(A)

(b)

EC-02616

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C) (C)

(D)

EC-02611

EC(H4SO)-6

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

(B)

(A)

(C)

(D)

EC-02611

2) Connect the connector to the drain valve. EC-02609

4) Secure the rear wiring harness with clip.

EC-02610

3) Install the canister to the vehicle. EC-02608

5) Attach all tubes to clips (D), and connect the quick connectors of the vent tube (A), canister drain tube (B) and charge tube (C). CAUTION: • Make sure there are no damage or dust on connections. If necessary, clean the seal surface of the pipe. • Make sure that the quick connector is securely connected.

EC(H4SO)-7

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

NOTE: Connect the quick connector as shown in the figure.

(a)

(b)

EC-02616

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C)

(C) (A)

(B)

(D) EC-02607

6) Install the rear mud guard LH. 7) Lower the vehicle. 8) Install the rear wheel LH.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb)

C: INSPECTION 1) Check that the canister has no deformation, cracks or other damages. 2) Check that the tube has no cracks, damage or loose part.

EC(H4SO)-8

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Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

5. Purge Control Solenoid Valve

• U6 model (B)

A: REMOVAL

(A)

1) Disconnect the ground cable from battery.

EC-02557

• U5 model (A)

IG-02107

2) Remove the air intake boot assembly. 3) Disconnect the purge control solenoid valve connector (A) and evaporation hose (B), and then remove the purge control solenoid valve. • U6 model

(B)

EC-02619

(A)

(A) To multifunction duct (B) To evaporation line

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) • U6 model (B)

EC-02556

• U5 model

(A)

(A)

(B)

EC-02556

• U5 model (B)

EC-02622

B: INSTALLATION

(A)

Install in the reverse order of removal. NOTE: Connect the evaporation hose as shown in the figure. (B)

EC(H4SO)-9

EC-02622

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Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

C: INSPECTION

• U6 model

1. PURGE CONTROL SOLENOID VALVE

2 1

1) Check that the purge control solenoid valve has no deformation, cracks or other damages. 2) Measure the resistance between the purge control solenoid valve terminals.

2 1 (A)

(B)

EC-02426

• U6 model Terminal No. 1 and 2

Standard 24±3 Ω (when 20°C (68°F)) EC-02559

• U5 model Terminal No. 1 and 2

Standard 24.5±1.5 Ω (when 20°C (68°F))

• U5 model

2 1

3) Check that air does not come out from (B) when air is blown into (A). • U6 model

(A)

(B)

(B) EC-02558

• U5 model (A)

(B) EC-02621

2. OTHER INSPECTIONS

(A)

Check that the evaporation hose has no cracks, damage or loose part. EC-02620

4) With terminal No. 1 connected to the battery positive terminal and terminal No. 2 to the battery ground terminal, check that air comes out from (B) when air is blown into (A).

EC(H4SO)-10

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EGR Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

6. EGR Valve A: REMOVAL For removal procedures, refer to “FU” section.

B: INSTALLATION For installation procedures, refer to “FU” section.

C: INSPECTION Refer to “FU” for inspection procedures.

EC(H4SO)-11

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Fuel Level Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

7. Fuel Level Sensor A: REMOVAL For removal procedures, refer to the “FU(H4SO)” section.

B: INSTALLATION For installation procedures, refer to the “FU(H4SO)” section.

C: INSPECTION For inspection procedures, refer to the “FU(H4SO)” section.

EC(H4SO)-12

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Fuel Temperature Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

8. Fuel Temperature Sensor

C: INSPECTION

A: REMOVAL

1) Check the fuel temperature sensor for deformation, cracks or other damages. 2) Measure the resistance between fuel temperature sensor terminals.

The fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, refer to “Fuel Level Sensor” for removal procedure.

CAUTION: Make sure of the circuit tester spec and do not apply a voltage of 3 V or more when measuring the resistance. Otherwise the fuel temperature sensor will be damaged.

1 2 3 4

(A) EC-02391

(A) Fuel temperature sensor

B: INSTALLATION

EC-02452

The fuel temperature sensor and fuel level sensor are integrated into one unit; therefore, refer to “Fuel Level Sensor” for installation procedure.

Temperature

Terminal No.

–10°C (14°F) 20°C (68°F) 50°C (122°F)

(A) EC-02391

(A) Fuel temperature sensor

EC(H4SO)-13

Standard 9.2±2.2 kΩ (at a set current of 0.5 mA)

2 and 3

2.5±0.2 kΩ (at a set current of 1.0 mA) 0.84+0.06 –0.05 kΩ (at a set current of 1.0 mA)

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Fuel Sub Level Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

9. Fuel Sub Level Sensor A: REMOVAL For removal procedures, refer to the “FU(H4SO)” section.

B: INSTALLATION For installation procedures, refer to the “FU(H4SO)” section.

C: INSPECTION For inspection procedures, refer to the “FU(H4SO)” section.

EC(H4SO)-14

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Fuel Tank Pressure Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

10.Fuel Tank Pressure Sensor

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

WARNING: Place “NO OPEN FLAMES” signs near the working area. 1) Disconnect the ground cable from battery.

Tightening torque: 7.35 N·m (0.7 kgf-m, 5.4 ft-lb)

EC-02599

C: INSPECTION IG-02107

2) Open the fuel filler lid and remove the fuel filler cap. 3) Lift up the vehicle. 4) Disconnect connector (A) from fuel tank pressure sensor. 5) Pull out the vacuum hose (B) from vehicle. 6) Remove the fuel tank pressure sensor from the bracket.

1. FUEL TANK PRESSURE SENSOR 1) Check that the fuel tank pressure sensor does not have deformation, cracks or other damages. 2) Connect dry-cell battery positive terminal to terminal No. 3 and dry-cell battery ground terminal to terminal No. 1, circuit tester positive terminal to terminal No. 2 and the circuit tester negative terminal to terminal No. 1. NOTE: • Use new dry-cell batteries. • Using circuit tester, check the voltage of a single dry-cell battery is 1.6 V or more. And also check the voltage of three batteries in series is between 4.8 V and 5.2 V.

(A)

(B)

3 2 1

EC-02597

7) Disconnect the pressure hose from fuel tank pressure sensor and remove the fuel tank pressure sensor. V

1.5V

EC-02598

1.5V

1.5V

4.8 5.2V FU-04486

3) Check the voltage at a normal atmospheric pressure.

EC(H4SO)-15

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Fuel Tank Pressure Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

NOTE: The atmospheric pressure at higher altitude is lower than normal. Therefore, the voltage is lower than the standard value. Terminal No.

Standard

2 (+) and 1 (–)

Approx. 2.5 V (when 25°C (77°F))

4) Connect the Mighty Vac to the pressure port (A) on the fuel tank pressure sensor.

(A) EC-02586

5) Check the voltage when generating vacuum and positive pressure using Mighty Vac. CAUTION: Be sure to apply pressure within a range of –10 — 20 kPa (–0.1 — 0.2 kgf/cm2, –1.45 — 2.90 psi). Otherwise the fuel tank pressure sensor will be damaged. Pressure –6.67 kPa (–0.07 kgf/cm2, –0.97 psi) 6.67 kPa (0.07 kgf/cm2, 0.97 psi)

Terminal No.

Standard Approx. 0.5 V (when 25°C (77°F))

2 (+) and 1 (–) Approx. 4.5 V (when 25°C (77°F))

2. OTHER INSPECTIONS Check that the hose has no cracks, damage or loose part.

EC(H4SO)-16

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Drain Filter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

11.Drain Filter A: SPECIFICATION Drain valve is a non-disassembled part, so do not remove the drain filter from drain valve. Refer to “Canister” for removal and installation procedures.

EC(H4SO)-17

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Drain Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

12.Drain Valve A: REMOVAL Drain valve is integrated with canister. Refer to “Canister” for removal procedure.

B: INSTALLATION Refer to “Canister” for the installation procedure.

C: INSPECTION Measure the resistance between drain valve terminals.

2 1

EC-02455

Terminal No. 1 and 2

Standard 20 — 30 Ω

EC(H4SO)-18

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PCV Hose Assembly EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

13.PCV Hose Assembly

B: INSTALLATION

A: REMOVAL

1) Install the PCV hose assembly (B) to the cylinder block RH and PCV pipe, and then connect the vacuum hose (A) to the PCV valve.

CAUTION: Do not remove except when the hose is broken. 1) Remove the air intake boot assembly. 2) Disconnect the vacuum hose (A) from PCV valve, and remove the PCV hose assembly (B) from cylinder block RH and PCV pipe.

NOTE: Use a new clamp for the PCV hose assembly, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS

NOTE: Pinch the clamp of the PCV hose assembly by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp. ST 18353AA000 CLAMP PLIERS

ST

ST ME-04374

(A) ME-04374

(B)

EC-02605 (A)

2) Install the air intake boot assembly.

(B)

C: INSPECTION Check the PCV hose assembly for cracks, damage or looseness. EC-02605

EC(H4SO)-19

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PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

14.PCV Valve

B: INSTALLATION

A: REMOVAL

1) Connect the vacuum hose (A) and PCV hose (B) to the PCV valve.

1) Remove the air intake boot assembly. 2) Disconnect the vacuum hose (A) and PCV hose (B) from the PCV valve and remove the PCV valve. NOTE: Pinch the clamp of the PCV hose (B) by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp. ST 18353AA000 CLAMP PLIERS

NOTE: Use a new clamp for the PCV hose (B), fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS ST

ST

ME-04374

ME-04374

(A)

(B) (A)

(B) EC-02606

2) Install the air intake boot assembly. EC-02606

C: INSPECTION 1. PCV VALVE 1) Check that the PCV valve has no deformation, cracks or other damages. 2) Check that air is discharged from (B) when air is blown into (A).

(B)

(A)

EC-02507

EC(H4SO)-20

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PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

3) Check that air does not come out from (B) when air is blown into (A).

(A)

(B)

EC-02508

2. OTHER INSPECTIONS Check the vacuum hose for cracks, damage or looseness.

EC(H4SO)-21

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PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(H4SO)-22

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INTAKE (INDUCTION)

IN(H4SO) 1. 2. 3. 4. 5. 6.

Page General Description ...................................................................................2 Air Cleaner Element ...................................................................................4 Air Cleaner Case ........................................................................................6 Air Intake Boot ............................................................................................8 Air Intake Duct ............................................................................................9 Resonator Chamber .................................................................................10

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General Description INTAKE (INDUCTION)

1. General Description A: COMPONENT (9) T1 (8) (16)

(7) T4 (4) (15)

(3) T3

(5) (6) (11)

(12) (2)

(13)

(10) (1)

T2 (14) T2

(17)

IN-02661

IN(H4SO)-2

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General Description INTAKE (INDUCTION) (1) (2) (3) (4) (5) (6) (7) (8)

Air intake duct Clip Resonator chamber Air cleaner case (front) Spacer Cushion Air cleaner element Air cleaner case (rear)

(9) (10) (11) (12) (13) (14) (15) (16)

Clip Clamp Cover Clip Air intake boot ASSY Clamp Cushion Mass air flow and intake air temperature sensor

B: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.

IN(H4SO)-3

(17)

Blow-by hose

Tightening torque:N·m (kgf-m, ft-lb) T1: 1 (0.1, 0.7) T2: 3 (0.3, 2.2) T3: 6 (0.6, 4.4) T4: 7.5 (0.8, 5.5)

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Air Cleaner Element INTAKE (INDUCTION)

2. Air Cleaner Element

5) Remove the clip (B) securing the upper side of air cleaner case.

A: REMOVAL 1) Disconnect the ground cable from battery.

(B)

(A)

IN-02749

6) Pull the air cleaner case (rear) backward of the vehicle, and remove the air cleaner element.

IG-02107

2) Disconnect the power steering oil pressure hose (suction hose) from the clip on the side of air cleaner case (rear).

IN-02664

B: INSTALLATION Install in the reverse order of removal.

IN-02762

3) Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B).

(A)

CAUTION: Be sure to use SUBARU genuine air cleaner element depending on the engine type when replacing the air cleaner elements. Using other air cleaner element may affect the engine performance. NOTE: • Check that there are no foreign objects in the air cleaner case. • When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.

(B)

IN-02748

4) Loosen the clamp (A) which connects the air cleaner case (rear) and air intake boot assembly.

IN-02438

IN(H4SO)-4

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Air Cleaner Element INTAKE (INDUCTION)

Tightening torque: Clamp (A) 3 N·m (0.3 kgf-m, 2.2 ft-lb)

(A)

IN-02750

C: INSPECTION 1) Check that the air cleaner element has no deformation, cracks or other damages. 2) Check the air cleaner element for excessive dirt.

IN(H4SO)-5

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Air Cleaner Case INTAKE (INDUCTION)

3. Air Cleaner Case

6) Remove the clip (B) from the air cleaner case (front).

A: REMOVAL 1) Disconnect the ground cable from battery.

(B)

(A)

IN-02749

7) Remove the air cleaner case (rear) and air cleaner element.

IG-02107

2) Remove the air intake duct. 3) Disconnect the power steering oil pressure hose (suction hose) from the clip on the side of air cleaner case (rear).

IN-02666

8) Remove the bolts (A) and nuts (B) which secure the air cleaner case (front) to the body. (B)

IN-02762

4) Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B). (A) (A) IN-02751

9) Remove the air cleaner case (front). (B)

IN-02748

5) Loosen the clamp (A) which connects the air cleaner case and air intake boot assembly.

IN(H4SO)-6

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Air Cleaner Case INTAKE (INDUCTION)

B: INSTALLATION 1) Install the bolt (A) and nut (B) which secure the air cleaner case (front) to the body.

4) Connect the connector (A) to the mass air flow and intake air temperature sensor and secure the harness with clip (B).

Tightening torque: Bolt (A) 6 N·m (0.6 kgf-m, 4.4 ft-lb) Nut (B) 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(A)

(B)

(B) IN-02748

5) Connect the power steering oil pressure hose (suction hose) to the clip on the side of air cleaner case (rear). (A) IN-02751

2) Install the air cleaner case (rear) and the air cleaner element. NOTE: When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install. IN-02762

6) Install the air intake duct. 7) Connect the ground cable to battery.

IN-02438

3) Install the clip (B) to the air cleaner case (front), then tighten the clamp (A) that connects the air cleaner case (rear) to the intake boot. IG-02107

Tightening torque: Clamp (A) 3 N·m (0.3 kgf-m, 2.2 ft-lb)

(B)

C: INSPECTION 1) Check that the air cleaner case has no deformation, cracks or other damages. 2) Check that the air intake boot has no cracks, damage or loose part.

(A)

IN-02749

IN(H4SO)-7

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Air Intake Boot INTAKE (INDUCTION)

4. Air Intake Boot A: REMOVAL 1) Remove the cover (A) and clip (B) from air intake boot assembly.

(A)

(B)

(B) IN-02668

2) Loosen the clamp (A) which connects the air intake boot assembly and air cleaner case. 3) Loosen the clamp (B) which connects the air intake boot assembly and throttle body.

(B)

(A)

IN-02669

4) Disconnect the blow-by hose and remove the air intake boot assembly.

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: Clamp (A), (B) 3 N·m (0.3 kgf-m, 2.2 ft-lb)

(B)

(A)

IN-02669

C: INSPECTION 1) Check that the air intake boot assembly does not have deformation, cracks or other damages. 2) Check there is no foreign matter in the air intake boot assembly.

IN(H4SO)-8

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Air Intake Duct INTAKE (INDUCTION)

5. Air Intake Duct A: REMOVAL 1) Detach the clip connecting the air intake duct to the front vehicle body, and remove the air intake duct.

IN-02752

B: INSTALLATION Install in the reverse order of removal.

C: INSPECTION 1) Check that the air intake duct has no deformation, cracks or other damages. 2) Inspect that no foreign objects are mixed in the air intake duct.

IN(H4SO)-9

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Resonator Chamber INTAKE (INDUCTION)

6. Resonator Chamber A: REMOVAL The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to “Air Cleaner Case” for removal procedure.

B: INSTALLATION The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to “Air Cleaner Case” for installation procedure.

C: INSPECTION Check that the resonator chamber has no deformation, cracks or other damages.

IN(H4SO)-10

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MECHANICAL

ME(H4SO) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

Page General Description ...................................................................................2 Compression ............................................................................................23 Idle Speed ................................................................................................24 Ignition Timing ..........................................................................................25 Intake Manifold Vacuum ...........................................................................26 Engine Oil Pressure .................................................................................27 Fuel Pressure ...........................................................................................28 Valve Clearance .......................................................................................29 Engine Assembly .....................................................................................31 Engine Mounting ......................................................................................38 Preparation for Overhaul ..........................................................................41 V-belt ........................................................................................................42 Crank Pulley .............................................................................................44 Timing Belt Cover .....................................................................................46 Timing Belt ...............................................................................................47 Cam Sprocket ..........................................................................................52 Crank Sprocket ........................................................................................53 Valve Rocker Assembly ...........................................................................54 Camshaft ..................................................................................................57 Cylinder Head ..........................................................................................61 Cylinder Block ..........................................................................................69 Oil Switching Solenoid Valve ...................................................................90 Intake and Exhaust Valve ........................................................................92 Piston .......................................................................................................93 Connecting Rod .......................................................................................94 Crankshaft ................................................................................................95 Engine Trouble in General .......................................................................96 Engine Noise ..........................................................................................102

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General Description MECHANICAL

1. General Description A: SPECIFICATION Model

2.5 L

Cylinder arrangement Valve system mechanism Bore × Stroke Displacement Compression ratio Compression pressure (at 200 — 300 rpm) Number of piston rings

Engine

mm (in) cm3 (cu in) kPa (kg/cm2, psi) Standard

Constant

Open Close

BTDC 0° ABDC 58°

Low speed

Open Close

BTDC 0° ABDC –10°

High speed

Open Close

BTDC 14° ABDC 62°

Open Close

BBDC 30° ATDC14°

Exhaust valve timing

Idle speed (For CVT model, select lever in “P” or “N” range. For MT model, gear shift lever in neutral position.)

1,020 — 1,275 (10.4 — 13.0, 148 — 185) Pressure ring: 2, Oil ring: 1

Intake valve timing

Valve clearance

Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Belt driven Single overhead camshaft 4 valve/cylinder 99.5 × 79.0 (3.92 × 3.11) 2,457 (149.94) 10.0

mm (in)

Intake Exhaust

0.20±0.04 (0.0079±0.0016) 0.25±0.04 (0.0098±0.0016)

No load

Standard

CVT model: 675±100 MT Model: 650±100

A/C ON

Standard

700 — 850±100

rpm

Ignition order

1→3→2→4

Ignition timing

CVT model: 15°±10°/675 MT Model: 10°±10°/650

BTDC/rpm Standard

ME(H4SO)-2

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General Description MECHANICAL

NOTE: US: Undersize OS: Oversize Belt tension adjuster Valve rocker arm

Camshaft

Cylinder head

Valve seat

Adjuster rod protrusion amount

mm (in)

Clearance between arm and shaft Rocker arm inside diameter Rocker shaft diameter Bending limit

mm (in) Standard mm (in) Standard mm (in) Standard mm (in) Constant Standard Intake Low speed Standard Cam lobe height mm (in) High speed Standard Exhaust Standard Cam base circle diameter mm (in) Standard Base circle step of adjacent intake mm (in) Standard cams (low speed and high speed)

0.020 — 0.054 (0.0008 — 0.0021) 22.020 — 22.041 (0.8669 — 0.8678) 21.987 — 22.000 (0.8656 — 0.8661) 0.025 (0.00098) 40.075 — 40.175 (1.5778 — 1.5817) 35.496 — 35.596 (1.3975 — 1.4014) 40.315 — 40.415 (1.5872 — 1.5911) 39.289 — 39.389 (1.5468 — 1.5507) 34.00 (1.3386)

Oil clearance Journal O.D. Cylinder head journal inner diameter Thrust clearance Warping limit (Mating surface with cylinder block)

0.055 — 0.090 (0.0022 — 0.0035) 31.928 — 31.945 (1.2570 — 1.2577) 32.000 — 32.018 (1.2598 — 1.2605) 0.030 — 0.090 (0.0012 — 0.0035)

mm (in) mm (in) mm (in) mm (in)

Grinding limit Standard height Seating angle between valve and valve seat Intake Contacting width of valve mm (in) and valve seat Exhaust Clearance between the valve guide and valve stem

mm (in)

Inside diameter Valve guide

Valve stem outer diameter Valve guide protrusion amount Head edge thickness

mm (in)

Valve Overall length

Standard Standard Standard Standard

0.035 (0.0014)

mm (in) mm (in)

0.1 (0.004) 97.5 (3.84) 90° 0.8 — 1.4 (0.03 — 0.055) 1.2 — 1.8 (0.047 — 0.071)

Standard Standard

Standard Standard mm (in) Intake mm (in) Exhaust Intake mm (in) Exhaust

Intake Exhaust mm (in)

0.8 — 1.2 (0.03 — 0.047) 1.0 — 1.4 (0.039 — 0.055)

Intake Exhaust mm (in)

120.6 (4.75) 121.7 (4.79) 55.2 (2.173)

N (kgf, lb)/mm (in) Lift

Squareness

Cylinder block

Warping limit (Mating surface with cylinder head) Grinding limit Standard height Taper Out-of-roundness Cylinder to piston clearance at 20°C (68°F):

0.035 — 0.062 (0.0014 — 0.0024) 0.040 — 0.067 (0.0016 — 0.0026) 6.000 — 6.012 (0.2362 — 0.2367) 5.950 — 5.965 (0.2343 — 0.2348) 5.945 — 5.960 (0.2341 — 0.2346) 20.0 — 21.0 (0.787 — 0.827) 16.5 — 17.5 (0.650 — 0.689)

Standard Standard

Set Tension/spring height

0.03 (0.001)

mm (in)

Intake Exhaust

Free length Valve spring

5.2 — 6.2 (0.205 — 0.244)

235.3 — 270.7 (24 — 27.6, 52.9 — 60.8)/ 45.0 (1.772) 578.9 — 639.9 (59.1 — 65.3, 130.3 — 143.9)/ 34.7 (1.366) 2.5°, 2.4 mm (0.094 in) or less

mm (in)

0.025 (0.00098)

mm (in) mm (in) mm (in) Standard mm (in) Standard

0.1 (0.004) 201.0 (7.91) 0.015 (0.0006) 0.010 (0.0004)

mm (in) Standard

–0.015 — 0.005 (–0.00059 — 0.00020)

Cylinder inner diameter boring limit (diameter)

mm (in)

ME(H4SO)-3

To 100.005 (3.9372)

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General Description MECHANICAL Piston grade point Piston

Outer diameter

mm (in) A Standard B mm (in) 0.25 (0.0098) OS 0.50 (0.0197) OS

Piston pin must be fitted into position with thumb at 20°C (68°F).

Degree of fit Piston pin

Clearance between piston pin hole and piston pin

Connecting rod and connecting rod bearing

Bushing of small end

Top ring Standard mm (in) Second ring Standard Oil ring Standard

Clearance between piston ring and piston ring groove

mm (in)

Top ring Standard Second ring Standard

0.004 — 0.008 (0.0002 — 0.0003) 0.20 — 0.35 (0.0079 — 0.0138) 0.37 — 0.52 (0.0146 — 0.0205) 0.20 — 0.50 (0.0079 — 0.0197) 0.040 — 0.080 (0.0016 — 0.0031) 0.030 — 0.070 (0.0012 — 0.0028)

Bend or twist per 100 mm (3.94 in) in length

mm (in)

Thrust clearance Oil clearance

mm (in) Standard mm (in) Standard

0.070 — 0.330 (0.0028 — 0.0130) 0.016 — 0.044 (0.0006 — 0.0017)

Standard 0.03 (0.0012) US mm (in) 0.05 (0.0020) US 0.25 (0.0098) US Clearance between piston pin and mm (in) Standard bushing

1.492 — 1.501 (0.0587 — 0.0591) 1.510 — 1.513 (0.0594 — 0.0596) 1.520 — 1.523 (0.0598 — 0.0600) 1.620 — 1.623 (0.0638 — 0.0639)

Service limit

Bearing size (Thickness at center)

Bending limit Crank pin

Crank journal

Crank pin outer diameter Crankshaft and crankshaft bearing

mm (in) Standard

Piston ring gap Piston ring

38.2 (1.504) 99.510 — 99.520 (3.9177 — 3.9181) 99.500 — 99.510 (3.9173 — 3.9177) 99.750 — 99.770 (3.9272 — 3.9280) 100.000 — 100.020 (3.9370 — 3.9378)

Crank journal outer diameter

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

0 — 0.022 (0 — 0.0009)

Out-of-roundness Cylindricality Grinding limit (dia.) Out-of-roundness Cylindricality Grinding limit (dia.) Standard 0.03 (0.0012) US mm (in) 0.05 (0.0020) US 0.25 (0.0098) US

0.035 (0.0014) 0.003 (0.0001) 0.004 (0.0002) To 51.750 (2.0374) 0.005 (0.0002) 0.006 (0.0002) To 59.758 (2.3527) 51.984 — 52.000 (2.0466 — 2.0472) 51.954 — 51.970 (2.0454 — 2.0461) 51.934 — 51.950 (2.0446 — 2.0453) 51.734 — 51.750 (2.0368 — 2.0374)

Standard 0.03 (0.0012) US mm (in) 0.05 (0.0020) US 0.25 (0.0098) US

59.992 — 60.008 (2.3619 — 2.3625) 59.962 — 59.978 (2.3607 — 2.3613) 59.942 — 59.958 (2.3599 — 2.3605) 59.742 — 59.758 (2.3520 — 2.3527)

#1, #3 Bearing size (Thickness at center) mm (in) #2, #4, #5 Thrust clearance Oil clearance

0.10 (0.0039)

Standard 0.03 (0.0012) US

1.998 — 2.011 (0.0787 — 0.0792) 2.017 — 2.020 (0.0794 — 0.0795)

0.05 (0.0020) US 0.25 (0.0098) US

2.027 — 2.030 (0.0798 — 0.0799) 2.127 — 2.130 (0.0837 — 0.0839)

Standard 0.03 (0.0012) US 0.05 (0.0020) US 0.25 (0.0098) US mm (in) Standard mm (in) Standard

2.000 — 2.013 (0.0787 — 0.0793) 2.019 — 2.022 (0.0795 — 0.0796) 2.029 — 2.032 (0.0799 — 0.0800) 2.129 — 2.132 (0.0838 — 0.0839) 0.030 — 0.115 (0.0012 — 0.0045) 0.010 — 0.030 (0.0004 — 0.0012)

ME(H4SO)-4

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General Description MECHANICAL

B: COMPONENT 1. V-BELT (5) (6)

(4)

(3)

(7)

T4 A (11)

T2

T4

(2)

(8)

T6

T5

A

B

(12)

B

T1 T7

T7

T5

(9) (10) C

(1)

C (13)

T7 T3

ME-04541

(1) (2)

V-belt V-belt cover bracket

(8) (9)

Idler pulley ASSY Stopper rod RH

(3) (4) (5) (6) (7)

V-belt tensioner ASSY Power steering pump bracket Generator Generator plate A/C compressor bracket A

(10) (11) (12) (13)

Stopper rod LH A/C compressor A/C compressor bracket B Front cushion rubber

ME(H4SO)-5

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: T3: T4: T5: T6: T7:

20 (2.0, 14.8) 22 (2.2, 16.2) 25 (2.5, 18.4) 26.5 (2.7, 19.5) 33 (3.4, 24.3) 36 (3.7, 26.6)

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General Description MECHANICAL

2. TIMING BELT

(5)

T1

(1) (2) T2 (3)

T5 (6)

(4) (7)

T4 (8)

T1

(12)

T3

T1 (9)

T4

T1

T4

(10)

(13)

(15)

(11) T5

(16) (14)

T6 T1 T6

ME-04539

(1)

Timing belt cover No. 2 RH

(9)

Automatic belt tension adjuster ASSY

(2) (3) (4) (5) (6) (7)

Timing belt guide (MT model) Crank sprocket Timing belt cover No. 2 LH Cam sprocket No. 1 Belt idler (A) Tensioner bracket

(10) (11) (12) (13) (14) (15)

Belt idler No. 2 Cam sprocket No. 2 Timing belt Front timing belt cover Timing belt cover LH Crank pulley (MT model)

(8)

Belt idler (B)

(16)

Crank pulley (CVT model)

ME(H4SO)-6

Tightening torque:N·m (kgf-m, ft-lb) T1: T2: T3: T4: T5: T6:

5 (0.5, 3.7) 9.75 (1.0, 7.2) 24.5 (2.5, 18.1) 39 (4.0, 28.8) 78 (8.0, 57.5)

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General Description MECHANICAL

3. CYLINDER HEAD AND CAMSHAFT (1) (20) (2)

T3 T5

T9 (4)

T6

(26)

T2

T6

(22)

(25) T4

(7) T7

(8) (3)

(23)

T3 (24) (6)

(5)

(8)

T8 (9) (10) (30)

(19)

T5

(8)

(14) (15) T8

(16) (7) T2

T6 (10) T4

(2) (17)

T3

(29)

(21)

(18)

(11) (28) (27)

(19) T2

(12) (5)

(13)

T6

T1 T7

(31) T3

(3) T7

ME(H4SO)-7

T9

ME-04540

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General Description MECHANICAL (1) (2)

Rocker cover RH Intake valve rocker ASSY

(16) (17)

Oil filler duct O-ring

(31)

(3) (4) (5) (6) (7) (8)

Exhaust valve rocker ASSY Camshaft cap RH Oil seal Camshaft RH PLUG Spark plug pipe gasket

(18) (19) (20) (21) (22) (23)

Rocker cover LH Stud bolt Rocker cover gasket RH Rocker cover gasket LH Oil switching solenoid valve RH Oil switching solenoid valve holder RH

Tightening torque:N·m (kgf-m, ft-lb) T1: 6 (0.6, 4.4) T2: 6.4 (0.7, 4.7) T3: 9.75 (1.0, 7.2) T4: 10 (1.0, 7.4) T5: 17 (1.7, 12.5)

(9) (10) (11)

Cylinder head RH Cylinder head gasket Cylinder head LH

(24) (25) (26)

(12)

Camshaft LH

(27)

Gasket Oil temperature sensor Variable valve lift diagnosis oil pressure switch RH Oil switching solenoid valve LH

(13)

Camshaft cap LH

(28)

(14) (15)

Oil filler cap Gasket

(29) (30)

Oil switching solenoid valve holder LH Gasket Variable valve lift diagnosis oil pressure switch LH

ME(H4SO)-8

Seal washer

T6: 18 (1.8, 13.3) T7: 25 (2.5, 18.4) T8: T9:

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General Description MECHANICAL

4. VALVE ROCKER ASSY

T2

T3

(1)

(1)

T1

(5) (2)

(2) (4) T2

T2

(3)

(3)

T3 ME-02691

(1) (2) (3)

Intake valve rocker ASSY Valve rocker nut Valve rocker adjusting screw

(4) (5)

Exhaust rocker shaft Exhaust valve rocker arm

ME(H4SO)-9

Tightening torque:N·m (kgf-m, ft-lb) T1: 6 (0.6, 4.4) T2: 9.75 (1.0, 7.2) T3: 25 (2.5, 18.4)

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General Description MECHANICAL

5. CYLINDER HEAD AND VALVE ASSEMBLY

(1)

(1)

(3)

(4)

(5)

(6)

(7)

(8)

(2) (2)

(3) (4) (9) (6) (7) (8)

ME-03322

(1) (2) (3)

Exhaust valve Intake valve Valve guide

(4) (5) (6)

Valve spring seat Intake valve oil seal Valve spring

ME(H4SO)-10

(7) (8) (9)

Retainer Retainer key Exhaust valve oil seal

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General Description MECHANICAL

6. CYLINDER BLOCK T5 T2

(31)

T2

T6 (1)

(32)

(7)

(5)

T10 (2) (29)

T2

(6)

(3) (4)

T6

(32) T9 (8)

T2

(28)

(10)

(11) (9) (4)

T2

T2

(10)

(3) T6 (27)

(15) (10)

(14)

T8 T9

T2

(26)

(23)

T3

(28)

(4)

T9

(29) (3)

(16)

T2

(10) (17)

(12)

(22) (33)

(35)

(38)

T6

(34)

T10

T2

T2

(37)

(24) T4 T2

T5 (36)

(21) (13) (25)

(30)

(18) T1 (20)

(19)

T7 ME-04434

ME(H4SO)-11

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General Description MECHANICAL (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Oil pressure switch Cylinder block RH Service hole plug Gasket Oil separator cover Water by-pass pipe Oil pump Front oil seal Rear oil seal O-ring

(18) (19) (20) (21) (22) (23) (24) (25) (26) (27)

Oil pan Drain plug Drain plug gasket Oil level gauge guide Water pump sealing Oil filter Gasket Water pump hose PLUG Seal

(11) (12) (13) (14) (15) (16)

Service hole cover Cylinder block LH Water pump Baffle plate Oil filter connector Oil strainer

(28) (29) (30) (31) (32) (33)

Seal washer Washer O-ring Engine rear hanger Oil pump seal Oil level gauge

(17)

Cylinder block lower

(34)

O-ring

ME(H4SO)-12

(35) (36) (37) (38)

O-ring Oil drain pipe O-ring Oil level switch

Tightening torque:N·m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 6.4 (0.7, 4.7) T3: 10 (1.0, 7.4) T4: First 12 (1.2, 8.7) Second 12 (1.2, 8.7) T5: T6: T7: T8: T9: T10:

16 (1.6, 11.8) 25 (2.5, 18.4) 41.7 (4.3, 30.8) 45 (4.6, 33.2) 70 (7.1, 51.6)

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General Description MECHANICAL

7. CRANKSHAFT AND PISTON (2) T2

(1) (3) T3 (10)

(4)

(9)

(5)

(12)

(6) (7) (10)

(13)

(8) (11)

(15) (13)

T1 (14)

(14) (11) T1

(13)

(8) (10)

(13)

(16)

(7) (6) (5)

(12) (10)

(9) (19) (18) (17) (18) (17) ME-04166

(1) (2) (3) (4) (5) (6) (7)

Reinforcement (CVT model) Drive plate (CVT model) Flywheel (MT model) Ball bearing (MT model) Top ring Second ring Oil ring

(9) (10) (11) (12) (13) (14) (15)

Piston pin Snap ring Connecting rod nut Connecting rod Connecting rod bearing Connecting rod cap Crankshaft

(8)

Piston

(16)

Woodruff key

ME(H4SO)-13

(17) (18) (19)

Crankshaft bearing #1, #3 Crankshaft bearing #2, #4 Crankshaft bearing #5

Tightening torque:N·m (kgf-m, ft-lb) T1: 45 (4.6, 33.2) T2: T3:

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General Description MECHANICAL

8. ENGINE MOUNTING

T4

(3)

T1 A

B B

T4 A

(2)

T3

(1) T2

T4

ME-04465

(1) (2)

Front mounting bracket Front cushion rubber

(3)

Engine mounting bracket

ME(H4SO)-14

Tightening torque:N·m (kgf-m, ft-lb) T1: 25 (2.5, 18.4) T2: 45 (4.6, 33.2) T3: 58 (5.9, 42.8) T4: 60 (6.1, 44.3)

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General Description MECHANICAL

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. • All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings. • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly. • Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel. • All removed parts, if to be reused, should be reinstalled in the original positions and directions. • Bolts, nuts and washers should be replaced with new parts as required. • Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks. • Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use. • Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection. • Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc. • Lift up or lower the vehicle when necessary. Make sure to support the correct positions.

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 18231AA010

DESCRIPTION CAM SPROCKET WRENCH

REMARKS Used for removing and installing cam sprocket. (LH side) NOTE: CAM SPROCKET WRENCH (499207100) can also be used.

1B022XU0

SUBARU SELECT MONITOR III KIT

Used for each inspection.

ST18231AA010

ST1B022XU0

ME(H4SO)-15

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 498267800

DESCRIPTION CYLINDER HEAD TABLE

REMARKS • Used for replacing valve guides. • Used for removing and installing valve spring.

498277200

STOPPER SET

Used for installing automatic transmission assembly to engine.

498457000

ENGINE STAND ADAPTER RH

Used together with ENGINE STAND (499817100).

498457100

ENGINE STAND ADAPTER LH

Used together with ENGINE STAND (499817100).

498497100

CRANKSHAFT STOPPER

Used for removing and installing drive plate.

ST-498267800

ST-498277200

ST-498457000

ST-498457100

ST-498497100

ME(H4SO)-16

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 498747300

DESCRIPTION PISTON GUIDE

REMARKS Used for installing piston in cylinder.

498857100

VALVE OIL SEAL GUIDE

Used for press-fitting of intake and exhaust valve guide oil seals.

499017100

PISTON PIN GUIDE

Used for installing piston pin, piston and connecting rod.

499037100

CONNECTING ROD BUSHING REMOVER AND INSTALLER

Used for removing and installing connecting rod bushing.

499587200

CRANKSHAFT OIL SEAL INSTALLER

• Used for installing crankshaft oil seal. • Used together with CRANKSHAFT OIL SEAL GUIDE (499597100).

ST-498747300

ST-498857100

ST-499017100

ST-499037100

ST-499587200

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 499587500

DESCRIPTION OIL SEAL INSTALLER

REMARKS • Used for installing the camshaft oil seal. • Used together with OIL SEAL GUIDE (499597000).

499587700

CAMSHAFT OIL SEAL INSTALLER

Used for installing cylinder head plug.

499097700

PISTON PIN REMOVER ASSY

Used for removing piston pin.

499207400

CAM SPROCKET WRENCH

Used for removing and installing cam sprocket. (RH side)

499497000

TORX® PLUS

Used for removing and installing camshaft cap.

ST-499587500

ST-499587700

ST-499097700

ST-499207400

ST-499497000

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 499587100

DESCRIPTION OIL SEAL INSTALLER

REMARKS Used for installing oil pump oil seal.

499597000

OIL SEAL GUIDE

• Used for installing the camshaft oil seal. • Used together with CAMSHAFT OIL SEAL INSTALLER (499587500).

499597100

CRANKSHAFT OIL SEAL GUIDE

• Used for installing crankshaft oil seal. • Used together with CRANKSHAFT OIL SEAL INSTALLER (499587200).

499718000

VALVE SPRING REMOVER

Used for removing and installing valve spring.

499767200

VALVE GUIDE REMOVER

Used for removing valve guides.

ST-499587100

ST-499597000

ST-499597100

ST-499718000

ST-499767200

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 499767400

DESCRIPTION VALVE GUIDE REAMER

REMARKS Used for reaming valve guides.

499767700

VALVE GUIDE ADJUSTER

Used for installing valve guides. (Intake side)

499767800

VALVE GUIDE ADJUSTER

Used for installing valve guides. (Exhaust side)

499817100

ENGINE STAND

• Stand used for engine disassembly and assembly. • Used together with ENGINE STAND ADAPTER RH (498457000) & LH (498457100).

499977100

CRANK PULLEY WRENCH

Used for removing and installing the crank pulley. (MT model)

ST-499767400

ST-499767700

ST-499767800

ST-499817100

ST-499977100

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 499977400

DESCRIPTION CRANK PULLEY WRENCH

REMARKS Used for removing and installing the crank pulley. (CVT model)

499987500

CRANKSHAFT SOCKET

Used for rotating crankshaft.

18854AA000

ANGLE GAUGE

Used for installing the crank pulley.

42099AE000

QUICK CONNECTOR RELEASE

Used for disconnecting quick connector of the engine compartment.

18471AA000

FUEL PIPE ADAPTER

Used for inspecting the fuel pressure.

ST-499977400

ST-499987500

ST18854AA000

ST42099AE000

ST18471AA000

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 42075AG690

DESCRIPTION FUEL HOSE

REMARKS Used for inspecting the fuel pressure. NOTE: This is the SUBARU genuine part.

18354AA000

VALVE ROCKER HOLDER

Used for installing the valve rocker assembly (intake). (2-piece set)

18258AA000

SPRING INSTALLER

Used for installing the valve rocker assembly (intake).

ST42075AG690

ST18354AA000

ST18258AA000

2. GENERAL TOOL TOOL NAME Compression gauge Vacuum gauge Oil pressure gauge Fuel pressure gauge Timing light

REMARKS Used for measuring compression. Used for measuring intake manifold vacuum. Used for measuring engine oil pressure. Used for measuring fuel pressure. Used for measuring ignition timing.

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Compression MECHANICAL

2. Compression

• If the compression pressure is out of standard, check or adjust the pistons, valves and cylinders.

A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1) After warming-up the engine, turn the ignition switch to OFF. 2) Make sure that the battery is fully charged. 3) Remove the fuse of fuel pump from main fuse box.

Compression (fully open throttle): Standard 1,020 — 1,275 kPa (10.4 — 13.0 kgf/cm2, 148 — 185 psi) Difference between cylinders 49 kPa (0.5 kgf/cm2, 7 psi) or less 12) After inspection, install the related parts in the reverse order of removal.

FU-04800

4) Start the engine and run it until it stalls. 5) After the engine stalls, crank it for five more seconds. 6) Turn the ignition switch to OFF. 7) Remove all spark plugs. 8) Fully open the throttle valve. 9) Check the starter motor for satisfactory performance and operation. 10) Install the compression gauge to the spark plug hole. NOTE: When using a screw-in type compression gauge, the screw should be less than 18 mm (0.71 in) long.

ME-00192

11) Crank the engine by starter motor and read the value when the needle of the compression gauge becomes stable. NOTE: • Perform at least two measurements per cylinder, and make sure that the values are correct.

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Idle Speed MECHANICAL

3. Idle Speed A: INSPECTION 1) Before checking the idle speed, check the following item: (1) Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the engine idle speed using Subaru Select Monitor. NOTE: • Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. • If idle speed is out of standard, refer to the General Diagnosis Table under “Engine Control System”. (1) Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C and etc. are OFF)

Idle speed (No load, and for CVT model, select lever in “P” or “N” range, for MT model, gear shift lever in neutral position.): Standard 675±100 rpm (CVT model) 650±100 rpm (MT model) (2) Check the idle speed when loaded. (Turn the A/C switch to “ON” and operate the compressor for at least one minute before measurement.) Idle speed (A/C on, and for CVT model, select lever in “P” or “N” range, for MT model, gear shift lever in neutral position.): Standard 700 — 850±100 rpm

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Ignition Timing MECHANICAL

4. Ignition Timing A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself at measurement.

Ignition timing [BTDC/rpm]: Standard 15°±10°/675 (CVT model) 10°±10°/650 (MT model) 6) After inspection, install the related parts in the reverse order of removal.

1. METHOD WITH SUBARU SELECT MONITOR 1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the ignition timing using Subaru Select Monitor. NOTE: If ignition timing is out of standard, check the ignition control system. Refer to “Engine Control System”.

Ignition timing [BTDC/rpm]: Standard 15°±10°/675 (CVT model) 10°±8°/650 (MT model)

2. METHOD WITH TIMING LIGHT 1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Stop the engine, and turn the ignition switch to OFF. 4) Connect the timing light to the power wire of #1 ignition coil. 5) Start the engine, turn the timing light to the crank pulley, and check the ignition timing through the timing belt cover gauge. NOTE: If the ignition timing is not correct, check the ignition control system. Refer to “Engine Control System”.

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Intake Manifold Vacuum MECHANICAL

5. Intake Manifold Vacuum A: INSPECTION 1) Warm up the engine. 2) Disconnect the brake booster vacuum hose from the intake manifold, and attach the vacuum gauge.

ME-04467

3) Keep the engine at idle speed and read the vacuum gauge indication. NOTE: Condition of engine inside can be diagnosed by observing the behavior of the vacuum gauge needle as described in table below.

Intake manifold vacuum (at idling, A/C OFF): Standard –60.0 kPa (–450 mmHg, –17.72 inHg) or more 4) After inspection, install the related parts in the reverse order of removal. Diagnosis of engine condition by inspection of intake manifold vacuum Vacuum gauge needle behavior Possible engine condition 1. Needle is steady but lower than standard value. This tenLeakage around intake manifold gasket, disconnection or damdency becomes more evident as engine temperature rises. age of vacuum hose 2. Needle intermittently drops to position lower than standard Leakage around cylinder value. 3. Needle drops suddenly and intermittently from standard Sticky valve value. 4. When engine speed is gradually increased, needle begins to Weak or broken valve springs vibrate rapidly at certain speed, and then vibration increases as engine speed increases. 5. Needle vibrates above and below standard value in narrow Defective ignition system range.

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Engine Oil Pressure MECHANICAL

6. Engine Oil Pressure A: INSPECTION 1) Disconnect the ground cable from battery.

Engine oil pressure: Standard 98 kPa (1.0 kgf/cm2, 14 psi) or more at 600 rpm 294 kPa (3.0 kgf/cm2, 43 psi) or more at 5,000 rpm 6) After inspection, install the related parts in the reverse order of removal.

IG-02107

2) Remove the oil pressure switch. 3) Attach the oil pressure gauge to the cylinder block.

ME-00196

4) Connect the ground cable to battery.

IG-02107

5) Start the engine, and measure the oil pressure. NOTE: • Standard value is based on an engine oil temperature of 80°C (176°F). • If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. • If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch.

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Fuel Pressure MECHANICAL

7. Fuel Pressure

4) Start the engine. 5) Measure the fuel pressure after warming up the engine.

A: INSPECTION CAUTION: • Before removing the fuel pressure gauge, release the fuel pressure. • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. 1) Release the fuel pressure. 2) Open the fuel filler lid and remove the fuel filler cap. 3) Disconnect the fuel delivery hose and connect the fuel pressure gauge.

NOTE: • The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. • Check or replace the fuel pump and fuel delivery line if the fuel pressure is out of the standard.

Fuel pressure: Standard 340 — 400 kPa (3.5 — 4.1 kgf/cm2, 49 — 58 psi) 6) After inspection, install the related parts in the reverse order of removal.

CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. (1) Attach ST to the fuel delivery pipe and push ST1 in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE (A)

ST

(B) FU-04950

(2) Connect the fuel pressure gauge with ST2 and ST3. NOTE: ST2 is a SUBARU genuine part. ST2 42075AG690 FUEL HOSE ST3 18471AA000 FUEL PIPE ADAPTER

ST2

ST1

ME-04213

(A) ST2 (B) ST3

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Valve Clearance MECHANICAL

8. Valve Clearance A: INSPECTION CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. NOTE: Inspection and adjustment of valve clearance should be performed while engine is cold. 1) Lift up the vehicle. 2) Remove the under cover. 3) Lower the vehicle. 4) Disconnect the ground cable from battery.

(4) Remove the bolts, then remove the rocker cover LH. 9) Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the arrow mark (A) on cam sprocket LH is at the top position, the #1 cylinder piston is at top dead center of the compression stroke. (A)

ME-00200

10) Measure #1 cylinder valve clearance by using thickness gauge (A).

IG-02107

5) Remove the timing belt cover LH.

NOTE: • Insert the thickness gauge (A) in as horizontally as possible with respect to the valve stem end face. • Lift up the vehicle, and then measure the exhaust valve clearances. • If the measured value is not within the inspection value, take notes of the value in order to adjust the valve clearance later on.

Valve clearance (inspection value): Intake 0.20±0.04 mm (0.0079±0.0016 in) Exhaust 0.25±0.04 mm (0.0098±0.0016 in) (A) ME-00199

6) Remove the fuel injector. 7) When inspecting #1 and #3 cylinders (1) Disconnect the ignition coil from spark plug on RH side. (2) Place a suitable container under the vehicle. (3) Disconnect the PCV hose from the rocker cover RH. (4) Remove the bolts, then remove the rocker cover RH. 8) When inspecting #2 and #4 cylinders (1) Disconnect the ignition coil from spark plug on LH side. (2) Place a suitable container under the vehicle. (3) Disconnect the PCV hose from the rocker cover LH.

ME-02696

11) Measure the valve clearance in #3, #2 and #4 cylinder in the same measurement procedure as #1 cylinder in this order. NOTE: • Be sure to set the cylinder pistons to their respective top dead centers on compression stroke before measuring valve clearances.

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Valve Clearance MECHANICAL

• By rotating the crank pulley clockwise every 180° from the state that #1 cylinder piston is on the top dead center of compression stroke, #3, #2 and #4 cylinder pistons come to the top dead center of compression stroke in this order. 12) If necessary, adjust the valve clearance. 13) After inspection, install the related parts in the reverse order of removal.

Valve clearance (adjustment value): Intake 0.20±0.04 mm (0.0079±0.0016 in) Exhaust 0.25±0.04 mm (0.0098±0.0016 in) Tightening torque: 9.75 N·m (1.0 kgf-m, 7.2 ft-lb)

NOTE: Use a new rocker cover gasket.

B: ADJUSTMENT CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. NOTE: Adjustment of valve clearance should be performed while engine is cold. 1) Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench. NOTE: When the arrow mark (A) on cam sprocket LH is at the top position, the #1 cylinder piston is at top dead center of the compression stroke. (A)

ME-00203

3) Adjust the valve clearance in #3, #2 and #4 cylinder in the same adjustment procedure as #1 cylinder in this order. NOTE: • Be sure to set the cylinder pistons to their respective top dead centers on compression stroke before adjusting valve clearances. • By rotating the crank pulley clockwise every 180° from the state that #1 cylinder piston is on the top dead center of compression stroke, #3, #2 and #4 cylinder pistons come to the top dead center of compression stroke in this order. 4) Ensure the valve clearances of each cylinder are within specifications. If necessary, readjust the valve clearances. 5) After measuring, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket.

ME-00200

2) Adjust the #1 cylinder valve clearance. (1) Loosen the valve rocker nut and screw. (2) Set a suitable thickness gauge. (3) While noting the valve clearance, tighten the valve rocker adjusting screw. (4) When the specified valve clearance is obtained, tighten the valve rocker nut. NOTE: • Insert a thickness gauge in a direction as horizontal as possible with respect to the valve stem end face. • Lift up the vehicle and adjust the exhaust valve clearances.

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Engine Assembly MECHANICAL

9. Engine Assembly

12) Remove the bolt, and disconnect the bulkhead harness connector from the engine harness connector and rear engine hanger.

A: REMOVAL 1) Change the front hood damper mounting position from (A) to (B), and completely open the front hood.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(B)

(A)

FU-05129

(B)

13) Slide the engine harness connector in the direction of the arrow and remove it from the rear engine hanger. ME-04396

2) Remove the V-belt covers. 3) Collect the refrigerant from A/C system. 4) Release the fuel pressure. 5) Disconnect the ground cable from battery. FU-05130

14) Disconnect connector (A) and terminal (B) from the generator, and remove the generator cord from clip (C). 15) Disconnect connector (D) from the A/C compressor. (A)

(B)

(C)

IG-02107

6) Open the fuel filler lid and remove the fuel filler cap. 7) Remove the air intake duct. 8) Remove the air intake boot assembly. 9) Remove the radiator. 10) Remove the front exhaust pipe. 11) Lower the vehicle.

(D)

ME-04240

16) Remove the clip which secure the generator cord to the intake manifold protector LH.

ME-04241

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Engine Assembly MECHANICAL

17) Disconnect the following hoses. (1) A/C pressure hose (2) Brake booster vacuum hose

(2) Insert the wrench into the crank pulley bolt, and rotate the crank pulley to remove the four bolts which hold torque converter clutch to the drive plate.

ME-00212

ME-04435

(3) Heater inlet hose and heater outlet hose

ME-04216

18) Lift up the vehicle. 19) Disconnect the ground cable on the engine side.

22) Disconnect the fuel delivery hose (A) and evaporation hose (B). CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. (1) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose (A). ST 42099AE000 QUICK CONNECTOR RELEASE (2) Remove the clip and disconnect the evaporation hose (B) from the evaporation pipe. (A)

ST

(B)

ME-04533

FU-04950

23) Support the engine with a lifting device and wire ropes.

ME-03377

20) Lower the vehicle. 21) Separate the torque converter clutch from the drive plate. (CVT model) (1) Remove the service hole plug.

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Engine Assembly MECHANICAL

24) Remove the stopper rod.

• MT model

ME-04422

25) Remove the bolt and nut which secure engine mounting to the cradle.

MT-00077

29) Lower the vehicle. CAUTION: When lifting down the vehicle, lower wire ropes at the same time. 30) Support the transmission with a garage jack. NOTE: Fine adjustment of the transmission height can be performed with this operation.

ME-04246 (A)

26) Lift up the vehicle. (B)

CAUTION: When lifting up the vehicle, raise up wire ropes at the same time. 27) Remove the bolts which secure the engine mounting onto the engine, and remove the engine mounting.

ME-00215

(A) TRANSMISSION (B) Garage jack

31) Separation of engine and transmission

ME-04247

28) Remove the bolts and nuts which hold the lower side of transmission to the engine. • CVT model

CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. (1) Remove the starter. (2) Attach the ST to the torque converter clutch case. (CVT model) ST 498277200 STOPPER SET

ST ME-00217 ME-04228

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Engine Assembly MECHANICAL

(3) Remove the bolts which hold the upper side of the transmission to the engine. • CVT model

• CVT model

ME-04227

• MT model ME-04227

• MT model

MT-01524 MT-01524

32) Remove the engine from vehicle. (1) Slightly raise the engine. (2) Adjust the height of the transmission with garage jack. (3) Move the engine horizontally until main shaft is withdrawn from clutch cover. (MT model) (4) Move the engine from engine compartment slowly.

4) Remove the garage jack. 5) Remove the ST from torque converter clutch case. (CVT model) NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST. ST 498277200 STOPPER SET

NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

B: INSTALLATION

ST

1) Apply a small amount of grease to splines of main shaft. (MT model)

Grease: NICHIMOLY N-130 or equivalent 2) Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. 3) Tighten the bolts which hold upper side of transmission to engine.

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

ME-00217

6) Install the starter. 7) Lift up the vehicle. CAUTION: When lifting up the vehicle, raise up wire ropes at the same time. 8) Attach the bolts and nuts which hold lower side of the transmission to engine.

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

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Engine Assembly MECHANICAL

• CVT model

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb)

ME-04228 ME-04246

• MT model 12) Install the stopper rod.

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb)

MT-00077

9) Set the engine mounting, and tighten the bolts which hold engine mounting to the engine. ME-04422

Tightening torque: 58 N·m (5.9 kgf-m, 42.8 ft-lb)

13) Remove the lifting device and wire ropes.

ME-04247

10) Lower the vehicle. CAUTION: When lifting down the vehicle, lower wire ropes at the same time. 11) Attach the bolts and nuts which secure engine mounting to the cradle.

LU-00222

14) Install the torque converter clutch to drive plate. (CVT model) (1) Insert the wrench into the crank pulley bolt, and rotate the crank pulley to attach the four bolts which hold torque converter clutch to the drive plate. NOTE: Be careful not to drop bolts into the torque converter clutch case.

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Engine Assembly MECHANICAL

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

19) Install the clip which secure the generator cord to the intake manifold protector LH.

ME-04241

ME-00212

(2) Fit the plug to service hole. 15) Lift up the vehicle. 16) Install the engine harness cover, and connect the ground cable.

20) Connect connector (D) to the A/C compressor. 21) Install the generator cord to clip (C), and connect connector (A) and terminal (B) to the generator.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

Tightening torque: 15 N·m (1.5 kgf-m, 11.1 ft-lb) (A)

(B)

(C)

(D)

ME-04240

ME-04533

22) Connect the engine harness connector to the bulkhead harness connector, attach it to the rear engine hanger, and fasten with bolt.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

ME-03377

17) Lower the vehicle. 18) Connect the following hoses. (1) Fuel delivery hose (2) Evaporation hose (3) Heater inlet hose and heater outlet hose (4) Brake booster vacuum hose (5) A/C pressure hose

FU-05129

23) Install the front exhaust pipe. 24) Install the radiator. 25) Install the air intake boot assembly. 26) Install the air intake duct.

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Engine Assembly MECHANICAL

27) Connect the ground cable to battery.

IG-02107

28) Fill engine coolant. 29) Charge the A/C system with refrigerant. 30) Check the CVTF level and replenish it if necessary. (CVT model) 31) Install the V-belt cover. 32) Change the front hood damper mounting position from (B) to (A), and close the front hood.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(B)

(A)

(B)

ME-04396

C: INSPECTION 1) Check that the pipes, hoses, connectors and clamps are securely connected. 2) Check that the engine coolant is up to specified level. 3) Check CVTF is at the specified level. (CVT model) 4) Start the engine and check for exhaust gas leakage, engine coolant leakage, fuel leakage, noise or vibration.

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Engine Mounting MECHANICAL

10.Engine Mounting

9) Remove the stopper rod.

A: REMOVAL 1) Change the front hood damper mounting position from (A) to (B), and completely open the front hood.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(B)

(A)

ME-04422

(B)

10) Remove the bolt and nut which secure engine mounting to the cradle.

ME-04396

2) Disconnect the ground cable from battery.

ME-04249

11) Lift up the vehicle.

IG-02107

3) Remove the radiator main fan motor assembly and radiator sub fan motor assembly. 4) Lift up the vehicle. 5) Remove the under cover. 6) Remove the front exhaust pipe. 7) Lower the vehicle. 8) Support the engine with a lifting device and wire ropes.

CAUTION: When lifting up the vehicle, raise up wire ropes at the same time. 12) Remove the bolts which secure the engine mounting onto the engine, and remove the engine mounting.

LU-00222

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ME-04247

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Engine Mounting MECHANICAL

B: INSTALLATION

5) Remove the lifting device and wire ropes.

1) Set the engine mounting, and tighten the bolts which hold engine mounting to the engine.

Tightening torque: 58 N·m (5.9 kgf-m, 42.8 ft-lb)

LU-00222

ME-04247

2) Lower the vehicle. CAUTION: When lifting down the vehicle, lower wire ropes at the same time. 3) Attach the bolts and nuts which secure engine mounting to the cradle.

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb)

6) Lift up the vehicle. 7) Install the front exhaust pipe. 8) Install the under cover. 9) Lower the vehicle. 10) Install the radiator main fan motor assembly and radiator sub fan motor assembly. 11) Connect the ground cable to battery.

IG-02107 ME-04249

4) Install the stopper rod.

12) Change the front hood damper mounting position from (B) to (A), and close the front hood.

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb)

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(B)

ME-04422

ME(H4SO)-39

(A)

(B)

ME-04396

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Engine Mounting MECHANICAL

C: DISASSEMBLY 1) Remove the front cushion rubber from the engine mounting bracket.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

ME-04251 ME-04251

2) Remove the front cushion rubber from the front mounting bracket.

E: INSPECTION Check that the engine mounting does not have deformation, cracks and any other damage.

ME-04252

D: ASSEMBLY 1) Install the front cushion rubber to the front mounting bracket.

Tightening torque: 45 N·m (4.6 kgf-m, 33.2 ft-lb)

ME-04252

2) Install the front cushion rubber to the engine mounting bracket.

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Preparation for Overhaul MECHANICAL

11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from vehicle body, attach the ST to the engine as shown in the figure. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817100 ENGINE STAND

ST3

ST2

ST1 ME-00221

2) In this section the procedures described under each index are all connected and stated in order. Engine overhaul will be completed when you go through all steps in the procedure. Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.

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V-belt MECHANICAL

12.V-belt

3) Remove the bolt securing the idler pulley to the A/C compressor bracket, and remove the idler pulley.

A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to vehicle body.

1. V-BELT 1) Remove the collector cover. 2) Remove the air intake duct. 3) Attach the tool to the V-belt tensioner assembly, and rotate the tool clockwise to loosen and remove the V-belt.

ME-04385

B: INSTALLATION 1. V-BELT Install in the reverse order of removal. CAUTION: • When reusing the V-belt, wipe off dust and water with cloth. • Do not use the V-belt if there is any oil, grease or coolant on the belt. • Be careful not to rub the V-belt end surface with bare hands; exposed core may cause injury. • Wipe off any dust, oil and water on the groove of each pulley with cloth. (E)

(F)

(G) (D)

(B) (A)

ME-04383 (C)

2. V-BELT TENSIONER ASSEMBLY AND IDLER PULLEY 1) Remove the V-belts. 2) Remove the bolt securing the V-belt tensioner assembly to the power steering pump bracket, and remove the V-belt tensioner assembly.

ME-04384

ME(H4SO)-42

ME-04386

(A) V-belt (B) V-belt tensioner ASSY (C) (D) (E) (F) (G)

Crank pulley Idler pulley Generator pulley Power steering pump pulley A/C compressor pulley

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V-belt MECHANICAL

2. V-BELT TENSIONER ASSEMBLY AND IDLER PULLEY Install in the reverse order of removal.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

C: INSPECTION 1) Check the V-belt for cracks, tear or wear. 2) Remove the air intake duct. 3) Check the V-belt tensioner assembly and idler pulley for deformation, cracks or other damages. 4) Check that the V-belt tension indicator (A) is within the limit (B).

(B)

(A)

ME-04385

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb)

ME-04384 ME-04387

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Crank Pulley MECHANICAL

13.Crank Pulley A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to vehicle body. 1) Remove the V-belts. 2) Use the ST to lock the crank pulley, and remove the crank pulley bolt. ST 499977400 CRANK PULLEY WRENCH (CVT MODEL) ST 499977100 CRANK PULLEY WRENCH (MT MODEL)

(2) Draw reference lines (A) and (B) using a marker to set the socket to the crank pulley bolt as shown in the figure. ST 499977400 CRANK PULLEY WRENCH (CVT MODEL) ST 499977100 CRANK PULLEY WRENCH (MT MODEL) NOTE: Set the socket onto the crank pulley bolt so that reference lines (A) and (B) is visible.

(A) (B) (a)

(A) (B) (b)

ST

ME-04524

3) Remove the crank pulley.

B: INSTALLATION ST

1. METHOD WITHOUT ANGLE GAUGE 1) Clean the crankshaft thread using compressed air. 2) Install the crank pulley. 3) Apply engine oil to the crank pulley bolt seat and thread. 4) Tighten the crank pulley bolts. (1) Use the ST to lock the crank pulley, and temporarily tighten the crank pulley bolt. ST 499977400 CRANK PULLEY WRENCH (CVT MODEL) ST 499977100 CRANK PULLEY WRENCH (MT MODEL)

Tightening torque: 47 N·m (4.8 kgf-m, 34.7 ft-lb)

(A)

(B) ME-04526

(a) When using 6-point socket (b) When using 12-point socket

(3) Draw end line (C) on ST using a marker at the same position as reference line (B) was drawn on the socket in step (2). ST 499977400 CRANK PULLEY WRENCH (CVT MODEL) ST 499977100 CRANK PULLEY WRENCH (MT MODEL)

(C)

ST

ST (B)

ME-04527 ME-04525

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Crank Pulley MECHANICAL

(4) Use the ST to lock the crank pulley, and tighten the crank pulley bolt to the angle where reference line (A) and end line (C) are aligned. ST 499977400 CRANK PULLEY WRENCH (CVT MODEL) ST 499977100 CRANK PULLEY WRENCH (MT MODEL)

Tightening torque: 47 N·m (4.8 kgf-m, 34.7 ft-lb)

NOTE: It should be approx. 60° when reference line (A) and end line (C) are aligned.

ST1

Tightening angle: 60°±5°

ME-04529

(3) Set the ST2, use the ST1 to lock the crank pulley, and tighten the crank pulley bolt to the specified angle. ST1 499977400 CRANK PULLEY WRENCH (CVT MODEL) ST1 499977100 CRANK PULLEY WRENCH (MT MODEL) ST2 18854AA000 ANGLE GAUGE

(C)

ST

(A)

ME-04528

5) Install the V-belts.

2. METHOD WITH ANGLE GAUGE 1) Clean the crankshaft thread using compressed air. 2) Install the crank pulley. 3) Apply engine oil to the crank pulley bolt seat and thread. 4) Tighten the crank pulley bolts. (1) Remove the radiator main fan motor assembly and radiator sub motor assembly. (2) Use the ST1 to lock the crank pulley, and temporarily tighten the crank pulley bolt. ST1 499977400 CRANK PULLEY WRENCH (CVT MODEL) ST1 499977100 CRANK PULLEY WRENCH (MT MODEL)

NOTE: Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.

Tightening angle: 60°±5°

ST1

ST2 ME-04530

(4) Install the radiator main fan motor assembly and radiator sub motor assembly. 5) Install the V-belts.

C: INSPECTION 1) Make sure the V belt is not worn or damaged. 2) Check the tension of the front side belt.

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Timing Belt Cover MECHANICAL

14.Timing Belt Cover

B: INSTALLATION

A: REMOVAL

1) Install the front timing belt cover (B).

NOTE: When replacing the single part, perform the work with the engine installed to vehicle body. 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the stopper rod.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb) 2) Install the timing belt cover LH (A). Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

(A) (B)

ME-04424

3) Install the stopper rod. ME-04422

4) Remove the timing belt cover LH (A). 5) Remove the front timing belt cover (B).

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb)

(A) (B)

ME-04422 ME-04424

4) Install the crank pulley. 5) Install the V-belts.

C: INSPECTION Check the timing belt cover for damage.

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Timing Belt MECHANICAL

15.Timing Belt A: REMOVAL NOTE: • When replacing the single part, perform the work with the engine installed to vehicle body. • When performing the work with the engine installed to body, the following parts must also be removed/installed. • Radiator main fan motor assembly • Radiator sub fan motor assembly • When performing the work with the engine installed to body, protect the radiator with cardboards or blankets.

(1) Use the ST to turn crankshaft. Align the mark (a) of sprocket to the mark (b) of oil pump, and then ensure the right side cam sprocket mark (c), cam cap and cylinder head matching surface (d) or left side cam sprocket mark (e), timing belt cover notch (f) are properly adjusted. ST 499987500 CRANKSHAFT SOCKET

ST ME-00231

(d)

(c)

1. TIMING BELT 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the timing belt cover. 4) Remove the timing belt guide. (MT model)

(a)

(b)

(f)

(e) ME-02533 ME-00065

5) If the alignment mark or arrow mark (which indicates the direction of rotation) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below.

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Timing Belt MECHANICAL

(2) Using white paint, put an alignment mark or an arrow mark on timing belts in relation to the crank sprocket and cam sprockets.

2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY 1) Remove the belt idler.

ME-02967

Z1: 46.8 teeth Z2: 43.7 teeth

ME-03449

2) Remove the automatic belt tension adjuster assembly.

Z1

Z2

ME-00234

6) Remove the belt idler (A). 7) Remove the belt idler No. 2 (B).

ME-00238

B: INSTALLATION 1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER 1) Prepare for installation of the automatic belt tension adjuster assembly.

(A)

(B)

ME-02968

8) Remove the timing belt.

ME-00236

CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down. • Do not use a lateral type vise. • Push the adjuster rod vertically. • Press-in the push adjuster rod gradually taking three minutes or more. • Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). • Push in the adjuster rod to the end face of the cylinder. However, do not push in the adjuster rod below the end face of the cylinder. Doing so may damage the cylinder. • Do not release the press pressure until stopper pin is completely inserted. (1) Attach the automatic belt tension adjuster assembly to vertical pressing tool.

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Timing Belt MECHANICAL

(2) Slowly push in the adjuster rod with a pressure of 165 N (16.8 kgf, 37.1 lbf) or more until the adjuster rod is aligned with the stopper pin hole in the cylinder.

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb)

ME-03449

ME-00239

(3) With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex wrench inserted into the stopper pin hole in cylinder, secure the adjuster rod.

2. TIMING BELT 1) Prepare for installation of the automatic belt tension adjuster assembly. 2) Align the mark (B) on oil pump with the mark (A) on crank sprocket.

(A)

(B)

ME-00350

2) Install the automatic belt tension adjuster assembly.

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb)

ME-03975

3) Turn the camshaft sprocket No. 2 using ST1, and turn the camshaft sprocket No. 1 using ST2 so that their alignment marks (A) come to top positions. ST1 18231AA010 CAM SPROCKET WRENCH NOTE: CAM SPROCKET WRENCH (499207100) can also be used. ST2 499207400 CAM SPROCKET WRENCH ME-00241

(A)

3) Install the belt idlers.

ME-00243

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Timing Belt MECHANICAL

4) While aligning the alignment mark (B) on timing belt with the mark (A) on sprockets, position the timing belt properly.

(1) Temporarily tighten the bolts mounting the timing belt guide.

ME-00230 ME-00244

5) Install the belt idler No. 2 (B).

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb) 6) Install the belt idler (A).

(2) Check and adjust the clearance between timing belt and timing belt guide by using thickness gauge.

Clearance: 1.0±0.5 mm (0.039±0.020 in)

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb)

ME-00246 (A)

(B)

ME-02968

7) After ensuring the marks on timing belt and camshaft sprockets are aligned, remove the stopper pin from belt tension adjuster.

(3) Tighten the bolts mounting the timing belt guide.

Tightening torque: 9.75 N·m (1.0 kgf-m, 7.2 ft-lb)

ME-00247 ME-00245

8) Install the timing belt guide. (MT model)

9) Install the timing belt cover. 10) Install the crank pulley. 11) Install the V-belts.

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Timing Belt MECHANICAL

C: INSPECTION 1. TIMING BELT 1) Check the timing belt teeth for breaks, cracks or wear. If any fault is found, replace the timing belt. 2) Check the condition on the back surface of the timing belt. If cracks are found, replace the timing belt. CAUTION: • Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. • Do not bend the timing belt sharply.

• Push the adjuster rod vertically. • Press the adjuster rod gradually taking three minutes or more. • Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). • Push in the adjuster rod to the end face of the cylinder. However, do not press the adjuster rod below the end face of the cylinder. Doing so may damage the cylinder. 4) Measure the amount of adjuster rod protrusion “H” from the end surface of the cylinder. If it is not within specifications, replace the automatic belt tension adjuster assembly with a new part.

Amount of adjuster rod protrusion H: 5.2 — 6.2 mm (0.204 — 0.244 in)

In radial diameter h: 60 mm (2.36 in) or more

H

h

ME-00249

ME-00248

2. AUTOMATIC BELT TENSION ADJUSTER 1) Visually check the oil seals for leaks, and rod ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster assembly. NOTE: Slight traces of oil at rod’s oil seal does not indicate a problem. 2) Check that the adjuster rod does not move when a pressure of 165 N (16.8 kgf, 37.1 lbf) is applied to it. This is to check adjuster rod stiffness. 3) If the adjuster rod is not stiff and moves freely when applying 165 N (16.8 kgf, 37.1 lb), check it using the following procedures: (1) Slowly press the adjuster rod down to the end surface of cylinder. Repeat this operation two to three times. (2) With the adjuster rod moved all the way up, apply a pressure of 165 N (16.8 kgf, 37.1 lb) to it, and check the adjuster rod stiffness. (3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new part.

3. BELT TENSION PULLEY 1) Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the automatic belt tension adjuster assembly with a new part if faulty. 2) Check the belt tension pulley for smooth rotation. Replace the automatic belt tension adjuster assembly with a new part if abnormal noise or excessive play occurs. 3) Check the belt tension pulley for grease leakage.

4. BELT IDLER 1) Check the belt idler for smooth rotation. Replace if noise or excessive play occurs. 2) Check the outer contacting surfaces of idler pulley for abnormal wear and scratches. 3) Check the belt idler for grease leakage.

CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down. • Do not use a lateral type vise.

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Cam Sprocket MECHANICAL

16.Cam Sprocket

• They can be distinguished by the L or R indication. ST 18231AA010 CAM SPROCKET WRENCH

A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to vehicle body. 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the timing belt cover. 4) Remove the timing belt. 5) Remove the camshaft position sensor. 6) Use the ST to lock the cam sprocket, and remove the cam sprocket bolt. ST 18231AA010 CAM SPROCKET WRENCH

NOTE: CAM SPROCKET WRENCH (499207100) can also be used.

NOTE: CAM SPROCKET WRENCH (499207100) can also be used.

Tightening torque: 78 N·m (8.0 kgf-m, 57.5 ft-lb)

Tightening torque: 78 N·m (8.0 kgf-m, 57.5 ft-lb)

ST ME-00250

ST

499207400

CAM SPROCKET WRENCH

ST

ST

ME-00251 ME-00250

ST

499207400

CAM SPROCKET WRENCH

ST

ME-00251

7) Remove the cam sprocket.

B: INSTALLATION 1) Install the cam sprocket. 2) Use the ST to lock the cam sprocket, and install the cam sprocket bolt. NOTE: • Do not confuse cam sprockets (LH) and (RH) during installation.

3) Install the camshaft position sensor. 4) Install the timing belt. 5) Install the timing belt cover. 6) Install the crank pulley. 7) Install the V-belts.

C: INSPECTION 1) Check the cam sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between cam sprocket and key. 3) Check the cam sprocket protrusion used for sensor for damage and contamination of foreign matter.

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Crank Sprocket MECHANICAL

17.Crank Sprocket A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to vehicle body. 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the timing belt cover. 4) Remove the timing belt. 5) Remove the crank sprocket.

ME-00103

B: INSTALLATION 1) Install the crank sprocket.

ME-00103

2) Install the timing belt. 3) Install the timing belt cover. 4) Install the crank pulley. 5) Install the V-belts.

C: INSPECTION 1) Check the crank sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between crank sprocket and key. 3) Check the crank sprocket protrusion used for sensor for damage and contamination of foreign matter.

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Valve Rocker Assembly MECHANICAL

18.Valve Rocker Assembly

NOTE: Leave two or three threads of bolts (i) and (j) engaged in order to retain the valve rocker assembly.

A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to vehicle body. Refer to “Valve Clearance” for preparation procedures.

1) Remove the ignition coil. 2) Disconnect the PCV hose and remove the rocker cover. 3) Remove the valve rocker assembly. (1) Use the ST to rotate the spring stopper in the direction of the arrow to remove it from adjuster pin. ST 18258AA000 SPRING INSTALLER

(d)

(a)

(j)

(h)

(b) (f)

(c) (e)

(g)

(i)

ME-02975

(3) Remove the valve rocker assembly. NOTE: Set the ST in the position shown in the drawing to remove the intake valve rocker assembly. ST 18354AA000 VALVE ROCKER HOLDER

ST ME-02704

ST

ME-02794

B: INSTALLATION 1) Install the valve rocker assembly. (1) Temporarily tighten the bolts equally in alphabetical order as shown in the figure.

(A) (B) (C) ME-02744

(A) Adjuster pin (B) Spring stopper (C) Spring

NOTE: • Do not temporarily tighten the bolts (i) and (j). • Set the ST in the position shown in the drawing to mount the intake valve rocker assembly. ST 18354AA000 VALVE ROCKER HOLDER

(2) Remove the bolts (a) through (j) in alphabetical sequence.

ST

ME-02794

(2) Tighten the bolts (a) through (h) to specified torque.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

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Valve Rocker Assembly MECHANICAL

(3) Tighten the bolts (i) through (j) to specified torque.

Tightening torque: 6 N·m (0.6 kgf-m, 4.4 ft-lb) (g)

(i)

(a)

(c)

(j) (e)

NOTE: Use a new rocker cover gasket. (2) Temporarily tighten the bolts in alphabetical order shown in the figure, tighten them in two stages.

Tightening torque: 1st 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) RH side

(h) (f)

(d)

(b)

(f)

(a)

(c)

ME-02703

(4) Use the ST to rotate the spring stopper in the direction of the arrow to fasten the adjuster pin. ST 18258AA000 SPRING INSTALLER (d)

(b)

(e)

ME-02715

LH side (f)

(a)

(c)

ST ME-02704

(d)

(b)

(e)

ME-02716

(3) Connect the PCV hose. 6) Install the ignition coil.

(A) (B)

C: DISASSEMBLY

(C) ME-02705

(A) Adjuster pin (B) Spring stopper (C) Spring

2) Remove the timing belt cover LH. 3) Adjust the valve clearance. 4) Install the timing belt cover LH.

NOTE: Intake valve rocker assembly cannot be disassembled. 1) Remove the exhaust valve rocker arm from the rocker shaft. NOTE: Keep all the removed parts in order for re-installing in their original positions. 2) Remove the nut and adjusting screw from exhaust valve rocker.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb) 5) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover.

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Valve Rocker Assembly MECHANICAL

D: ASSEMBLY NOTE: Intake valve rocker assembly cannot be disassembled. 1) Install the adjusting screw and nut to the exhaust valve rocker. 2) Insert the exhaust valve rocker arm to rocker shaft. NOTE: Valve rocker arms, and rocker shaft have identification marks. Make sure the parts with same markings are properly assembled.

Rocker arm inside diameter: 22.020 — 22.041 mm (0.8669 — 0.8678 in) Rocker shaft diameter: 21.987 — 22.000 mm (0.8656 — 0.8661 in) 3) If the roller or valve contact surface of valve rocker arm is worn or dented excessively, replace the valve rocker arm. 4) Check that the valve rocker arm roller rotates smoothly. If not, replace the valve rocker arm.

E: INSPECTION 1. INTAKE VALVE ROCKER ASSEMBLY 1) If the roller or valve contact surface of valve rocker arm is worn or dented excessively, replace the valve rocker assembly. 2) Check that the valve rocker arm roller rotates smoothly. If not, replace the valve rocker assembly.

2. EXHAUST VALVE ROCKER ASSEMBLY 1) Measure the inner diameter of valve rocker arm and outer diameter of valve rocker shaft, and confirm the difference (oil clearance) between the two values.

Clearance between arm and shaft: Standard 0.020 — 0.054 mm (0.0008 — 0.0021 in)

ME-02706

ME-00257

2) If the oil clearance exceeds the limit, replace the valve rocker arm or shaft, whichever shows the greater amount of wear.

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Camshaft MECHANICAL

19.Camshaft

(1) Remove the bolts (a) and (b) in alphabetical sequence.

A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to vehicle body. Refer to “Valve Clearance” for preparation procedures.

1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the timing belt cover. 4) Remove the timing belt. 5) Remove the cam sprocket. 6) Remove the timing belt cover No. 2 LH. 7) Remove the timing belt cover No. 2 RH. NOTE: Do not damage or lose the seal rubber when removing the timing belt covers.

(a)

(b)

ME-02707

(2) Equally loosen the bolts (c) through (j) all the way in alphabetical sequence. (j)

(h)

(d)

(f)

(e) (c) (g)

(i)

ME-02708

(3) Remove the bolts (k) through (p) in alphabetical sequence using ST. ST 499497000 TORX® PLUS (n)

(p)

(l)

ME-00258

8) Remove the tensioner bracket. (m) (k) (o)

ME-02709

(4) Remove the camshaft cap. 12) Remove the camshaft. 13) Remove the oil seal. 14) Remove the plug from rear side of camshaft. ME-00259

9) Remove the camshaft position sensor support. (LH side only) 10) Remove the valve rocker assembly. 11) Remove the camshaft cap.

CAUTION: Do not scratch the journal surface when removing the oil seal. 15) Similarly, remove the camshaft RH and related parts.

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Camshaft MECHANICAL

B: INSTALLATION 1) Apply a thin coat of engine oil to camshaft journals, and install the camshaft. 2) Install the camshaft cap. (1) Apply liquid gasket to the mating surfaces of camshaft cap.

(4) Tighten the TORX® bolts (e) through (j) in alphabetical sequence using the ST. ST 499497000 TORX® PLUS

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb) (e)

(g)

(i)

NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent (h) (j) (f)

ME-02712

(5) Tighten the bolts (k) through (r) in alphabetical sequence.

Tightening torque: 9.75 N·m (1.0 kgf-m, 7.2 ft-lb) (k)

(m)

ME-02710

NOTE: Apply a coat of liquid gasket of 3 mm (0.12 in) in diameter (A) along the edge (B) of camshaft cap (C) mating surface.

(q)

(o)

(p)

(A)

(r) (n)

ME-02713

(6) Tighten the bolts (s) and (t) in alphabetical sequence.

(B) (C)

NOTE: • Use a new seal washer. • Install and tighten the seal washer to the bolt. ME-00265

(2) Temporarily tighten the bolts (a) through (d) in alphabetical sequence.

(c)

(l)

Tightening torque: 9.75 N·m (1.0 kgf-m, 7.2 ft-lb)

(a)

(s)

(t) (b) (d) ME-02711

(3) Install the valve rocker assembly.

ME-02714

3) Apply a coat of engine oil to camshaft oil seal periphery and oil seal lips and install the oil seal (A) on camshaft using ST1 and ST2.

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NOTE: Use a new oil seal. ST1 499597000 OIL SEAL GUIDE ST2 499587500 OIL SEAL INSTALLER

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

ST1

ST2

ME-00274

(A) ME-02596

4) Apply a coat of engine oil to plug periphery and install the plug (A) using ST. ST 499587700 CAMSHAFT OIL SEAL INSTALLER

(A)

10) Install the cam sprocket. 11) Install the timing belt. 12) Adjust the valve clearance. 13) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. (2) Temporarily tighten the bolts in alphabetical order shown in the figure, tighten them in two stages.

ST

ME-02717

5) Install the camshaft position sensor support. (LH side only)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 6) Similarly, install the parts on right-hand side. 7) Install the tensioner bracket.

Tightening torque: 1st 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) RH side (f)

(a)

(c)

Tightening torque: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

(d)

(b)

(e)

ME-02715

LH side (f)

(a)

(c)

ME-00273

8) Install the timing belt cover No. 2 RH.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb) 9) Install the timing belt cover No. 2 LH. (d)

ME(H4SO)-59

(b)

(e)

ME-02716

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Camshaft MECHANICAL

(3) Connect the PCV hose. 14) Install the ignition coil. 15) Install the timing belt cover. 16) Install the crank pulley. 17) Install the V-belts.

Base circle step of adjacent intake cams (low speed and high speed): Standard 0.03 mm (0.001 in) or less

H

C: INSPECTION 1) Measure the bend, and repair or replace if necessary.

Camshaft bend limit: 0.025 mm (0.00098 in)

A

ME-00276

5) Measure the outer diameter of camshaft journal and inner diameter of cylinder head journal, and confirm the difference (oil clearance) between the two values. If the oil clearance is not within the standard, replace the camshaft or cylinder head as necessary. Unit: mm (in)

ME-00275

2) Check the journal for damage and wear. Replace if faulty. 3) Check the cam face condition, and remove the minor faults by grinding with oil stone. Replace if there is uneven wear, etc. 4) Measure the Cam height “H”, Cam base circle diameter “A”, and base circle step of adjacent intake cams (low speed and high speed). If it exceeds the standard or offset wear occurs, replace it.

Oil clearance

Standard

0.055 — 0.090 (0.0022 — 0.0035)

Camshaft journal O.D.

Standard

31.928 — 31.945 (1.2570 — 1.2577)

Cylinder head journal inner diameter

Standard

32.000 — 32.018 (1.2598 — 1.2605)

6) Measure the thrust clearance of camshaft with the dial gauge set at end of camshaft. If the thrust clearance is not within the standard or there is offset wear, replace the camshaft caps and cylinder head as a set. If necessary, replace the camshaft.

Camshaft thrust clearance: Standard 0.030 — 0.090 mm (0.0012 — 0.0035 in)

Cam lobe height H:

Intake

Exhaust

Unit: mm (in) 40.075 — 40.175 (1.5778 — 1.5817)

Constant

Standard

Low speed

Standard

35.496 — 35.596 (1.3975 — 1.4014)

High speed

Standard

40.315 — 40.415 (1.5872 — 1.5911)

Standard

39.289 — 39.389 (1.5468 — 1.5507)

Cam base circle diameter A: Standard 34.00 mm (1.3386 in)

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Cylinder Head MECHANICAL

20.Cylinder Head

12) While tapping the cylinder head with a plastic hammer, separate it from cylinder block. Remove the bolts (a) and (c) to remove cylinder head.

A: REMOVAL NOTE: • When replacing the single part, perform the work with the engine installed to vehicle body. Refer to “Valve Clearance” for preparation procedures.

• When performing the work with the engine installed to body, the following parts must also be removed/installed. Front exhaust pipe 1) Remove the V-belts. 2) Remove the intake manifold. 3) Remove the crank pulley. 4) Remove the timing belt cover. 5) Remove the timing belt. 6) Remove the cam sprocket. 7) Remove the bolt which holds A/C compressor bracket onto cylinder head. 8) Remove the valve rocker assembly. 9) Remove the camshaft. 10) Remove the oil level gauge guide. (LH side) 11) Remove the cylinder head bolts in alphabetical sequence as shown in the figure. NOTE: Leave bolts (a) and (c) engaged by three or four threads to prevent the cylinder head from falling. (c)

(e)

(a)

(b) (f) (d)

ME-02745

(c)

(e)

(a)

(b) (f) (d)

ME-02745

13) Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. 14) Similarly, remove the right side cylinder head.

B: INSTALLATION 1) Install the cylinder head to the cylinder block. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. NOTE: Use a new cylinder head gasket. (1) Clean the bolt threads and the bolt holes in the cylinder block. CAUTION: To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc. (2) Apply a sufficient coat of engine oil to the washer and bolt thread. (3) Tighten all bolts to 40 N·m (4.1 kgf-m, 29.5 ft-lb) in alphabetical order. (4) Retighten all bolts to 95 N·m (9.7 kgf-m, 70.1 ft-lb) in alphabetical order. CAUTION: If the bolt makes stick-slip sound during tightening, repeat the procedure from step (1). In this case, the cylinder head gasket can be reused. (5) Loosen all the bolts by 180° in the reverse order of installing, and loosen them further by 180°. (6) Tighten all bolts to 10 N·m (1.0 kgf-m, 7.4 ftlb) in alphabetical order. (7) Retighten all bolts to 30 N·m (3.1 kgf-m, 22.1 ft-lb) in alphabetical order. (8) Retighten all bolts to 60 N·m (6.1 kgf-m, 44.3 ft-lb) in alphabetical order.

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(9) Retighten all bolts by 80 — 90° in alphabetical order. (10) Retighten all bolts by 40 — 45° in alphabetical order.

RH side (f)

(a)

(c)

CAUTION: The tightening angle of the bolt should not exceed 45°. (11) Retighten bolts (a) and (b) by 40 — 45°. CAUTION: Make sure the total “tightening angle” of steps (10) and (11) does not exceed 90°.

(d)

(b)

(e)

ME-02715

LH side (f)

(a)

(f)

(a)

(c)

(c)

(d) (b) (e)

ME-02746

(d)

2) Install the oil level gauge guide. (LH side)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 3) Install the camshaft. 4) Install the valve rocker assembly. 5) Install the A/C compressor bracket on cylinder head. Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb) 6) Install the cam sprocket. 7) Install the timing belt. 8) Adjust the valve clearance. 9) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover.

(b)

(e)

ME-02716

10) Install the timing belt cover. 11) Install the crank pulley. 12) Install the intake manifold. 13) Install the V-belts.

C: DISASSEMBLY 1) Place the cylinder head on the ST. ST 498267800 CYLINDER HEAD TABLE 2) Compress the valve spring and remove the valve spring retainer key using ST. Remove each valve and valve spring. ST 499718000 VALVE SPRING REMOVER

NOTE: Use a new rocker cover gasket. (2) Temporarily tighten the bolts in alphabetical order shown in the figure, tighten them in two stages.

Tightening torque: 1st 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

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Cylinder Head MECHANICAL

NOTE: • Keep all the removed parts in order for re-installing in their original positions. • Mark each valve to prevent confusion. • Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. • For removal and installation procedures of the valve guide, intake valve oil seal and exhaust valve oil seal, refer to “INSPECTION”.

ST

ME-00280

D: ASSEMBLY

(8)

(1)

(5)

(3)

(7) (11)

(2)

(4)

(6)

(9)

(12) (10) (13) (14)

ME-03110

(1) (2) (3) (4) (5)

Valve Valve guide Valve spring seat Oil seal Valve spring

(6) (7) (8) (9) (10)

Retainer Retainer key Spark plug gasket Camshaft Oil seal

ME(H4SO)-63

(11) (12) (13) (14)

PLUG Camshaft cap Valve rocker ASSY Seal washer

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Cylinder Head MECHANICAL

1) Install the valve spring and valve. (1) Coat the stem of each valve with engine oil and insert the valve into valve guide.

E: INSPECTION

NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. (2) Set the cylinder head on ST. ST 498267800 CYLINDER HEAD TABLE (3) Install the valve spring and retainer.

1) Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Place the cylinder head on the ST. ST 498267800 CYLINDER HEAD TABLE 3) Measure the warping of the cylinder head surface that mates with cylinder block using a straight edge (A) and thickness gauge (B). If the warping exceeds the limit, correct the surface by grinding it with a surface grinder.

NOTE: Be sure to install the valve spring with its closecoiled end facing the cylinder head. (4) Set the ST to the valve spring. ST 499718000 VALVE SPRING REMOVER

1. CYLINDER HEAD

Warping limit: 0.035 mm (0.0014 in)

ST

Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder head: 97.5 mm (3.84 in) ME-00280

(5) Compress the valve spring and fit the valve spring retainer key.

(B)

NOTE: Uneven torque for the cylinder head bolts can cause warpage. When reassembling, pay special attention to the torque so as to tighten evenly. (A)

(C) (B)

(B)

(A) (C)

ST ME-00285

ME-02816

(A) Retainer key (B) Valve spring (C) Retainer

(6) After installing, tap the valve spring retainers lightly with a plastic hammer for better seating.

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Cylinder Head MECHANICAL

2. VALVE SEAT Inspect the intake and exhaust valve seats, and correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are replaced.

Contacting width of valve and valve seat W: Standard Intake (A) 0.8 — 1.4 mm (0.03 — 0.055 in) Exhaust (B) 1.2 — 1.8 mm (0.047 — 0.071 in)

(A) ME-00763

(A) Valve guide

Y (A)

W

(B)

X

W

ME-00397 ME-00289

2) If the clearance between the valve guide and valve stem exceeds the standard, replace the valve guide or valve itself, whichever shows greater amount of wear or damage. See the following procedure for valve guide replacement.

Valve guide inner diameter: 6.000 — 6.012 mm (0.2362 — 0.2367 in) ME-00287

3. VALVE GUIDE 1) Check the clearance between valve guide and valve stem. The clearance can be checked by measuring respectively the outer diameter of valve stem with a micrometer and the inner diameter of valve guide with a caliper gauge.

Clearance between the valve guide and valve stem: Standard Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in) Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)

Valve stem outer diameters: Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in) Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in) (1) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides fit the holes in ST1. (2) Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 498267800 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER

ST2

ST1 ME-00290

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Cylinder Head MECHANICAL

(3) Turn the cylinder head upside down and place the ST as shown in the figure. Intake side ST 499767700 VALVE GUIDE ADJUSTER Exhaust side ST 499767800 VALVE GUIDE ADJUSTER

Valve guide protrusion amount L: Intake 20.0 — 21.0 mm (0.787 — 0.827 in) Exhaust 16.5 — 17.5 mm (0.650 — 0.689 in)

L ST

(A)

(A)

ME-00293 ME-00291

(A) Valve guide (A) Valve guide

(4) Before installing a new valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head. (5) Coat a new valve guide with sufficient oil, put it into the cylinder head, and insert the ST1 into the valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER Intake side ST2 499767700 VALVE GUIDE ADJUSTER Exhaust side ST2 499767800 VALVE GUIDE ADJUSTER

(7) Ream the inside of valve guide using ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. NOTE: • Apply engine oil to the ST when reaming. • If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone. • If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. ST 499767400 VALVE GUIDE REAMER

ST1 ST2

ME-00294 ME-00292

(6) Check the valve guide protrusion amount “L”.

(8) After reaming, clean the valve guide to remove chips. (9) Recheck the contact condition between valve and valve seat after replacing the valve guide.

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Cylinder Head MECHANICAL

4. INTAKE AND EXHAUST VALVE

5. VALVE SPRING

1) Inspect the flange and valve stem of valve, and replace the valve with a new part if damaged, worn, deformed, or if dimension “H” in the figure is outside of the specified limit.

1) Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table. 2) To measure the squareness of the valve spring, stand the valve spring on a surface plate and measure its deflection at the top of valve spring using a right angle gauge.

Head edge thickness H: Intake (A) Standard 0.8 — 1.2 mm (0.03 — 0.047 in)

Free length

Exhaust (B) Standard 1.0 — 1.4 mm (0.039 — 0.055 in)

Tension/spring height N (kgf, lb)/mm (in) Squareness

mm (in) 55.2 (2.173) 235.3 — 270.7 (24 — 27.6, 52.9 — 60.8) Set /45.0 (1.772) 578.9 — 639.9 (59.1 — 65.3, 130.3 — 143.9) Lift /34.7 (1.366) 2.5°, 2.4 mm (0.094 in) or less

(A)

H

ME-00283

(B)

6. INTAKE AND EXHAUST VALVE OIL SEAL H

ME-00758

2) Put a small amount of grinding compound on the valve seat surface, and lap the valve and valve seat surface. Replace with a new valve oil seal after lapping. NOTE: It is possible to differentiate between the intake valve and the exhaust valve by their overall length.

Valve overall length: Intake 120.6 mm (4.75 in) Exhaust 121.7 mm (4.79 in)

1) For the following, replace the oil seal with a new part. See the procedure 2) and subsequent for replacement procedures. • When the lip is damaged. • When the spring is out of the specified position. • When readjusting the surfaces of valve and valve seat. • When replacing the valve guide. 2) Place the cylinder head on ST1, and use ST2 to press-fit the oil seal. ST1 498267800 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE NOTE: • Apply engine oil to oil seal before press-fitting. • When press-fitting the oil seal, do not use a hammer or strike in. • The intake valve oil seals and exhaust valve oil seals are distinguished by their colors.

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Cylinder Head MECHANICAL

Color of rubber part: Intake [Gray] Exhaust [Green] ST2

ST1

ME-00284

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Cylinder Block MECHANICAL

21.Cylinder Block

CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.

A: REMOVAL NOTE: Before conducting this procedure, drain the engine oil completely. 1) Remove the V-belts. 2) Remove the intake manifold. 3) Remove the crank pulley. 4) Remove the timing belt cover. 5) Remove the timing belt. 6) Remove the crank sprocket. 7) Remove the generator and A/C compressor with their brackets. 8) Remove the cylinder head. 9) Remove the drive plate. (CVT model) 10) Remove the clutch disc and cover. (MT model)

11) Remove the oil separator cover. 12) Remove the water by-pass pipe for heater. 13) Remove the water pump. 14) Remove the bolt which secures the oil pump to the cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.

ME-00138

16) Remove the front oil seal from the oil pump. 17) Remove the oil pan and cylinder block lower. (1) Set the part so that the cylinder block LH is on the upper side. (2) Remove the bolts which secure the oil pan to the cylinder block lower. (3) Insert an oil pan cutter blade into the gap between cylinder block lower and oil pan, and remove the oil pan. CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter. (4) Remove the bolts which secure the cylinder block lower to the cylinder block, and remove the cylinder block lower by using flat tip screwdriver. CAUTION: Insert the flat tip screwdriver to the position shown in the figure, and be careful not to damage the mating surface of the cylinder block and cylinder block lower.

ME-04426

LU-00015

15) Remove the oil pump from cylinder block using a flat tip screwdriver.

18) Remove the oil strainer. 19) Remove the baffle plate. 20) Remove the oil filter.

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Cylinder Block MECHANICAL

21) Remove the water pipe assembly.

ME-00300

(2)

(1)

(3) (4) (6) (4)

(3)

(5)

(4) (2)

(3)

(1)

(8) (4)

(7)

(3) (1)

(2) ME-02889

(1) (2) (3)

Service hole plug Gasket Snap ring

(4) (5) (6)

Piston pin Service hole cover O-ring

ME(H4SO)-70

(7) (8)

Seal washer Washer

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Cylinder Block MECHANICAL

22) Remove the service hole plugs using a hexagon wrench [14 mm].

ME-00140

23) Remove the service hole cover. 24) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.

ME-00141

25) Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.

ST

ME-03325

26) Similarly draw out the piston pins from #3 and #4 pistons. 27) Remove the cylinder block connecting bolt on the RH side. 28) Loosen the cylinder block connecting bolt on the LH side by 2 to 3 turns. 29) Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.

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Cylinder Block MECHANICAL

30) Separate the cylinder block LH and RH. NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.

(5) (7) (1) (4)

(2) (4)

(6)

(3)

(1)

(5) ME-02890

(1) (2) (3)

Cylinder block Rear oil seal Crankshaft

(4) (5)

Crankshaft bearing Piston

31) Remove the rear oil seal. 32) Remove the crankshaft along with the connecting rod. 33) Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: • Press the crankshaft bearing at the end opposite to locking lip to remove. • Be careful not to confuse the crankshaft bearing combination. 34) Remove each piston from the cylinder block using a wooden bar or hammer handle. NOTE: Be careful not to confuse the original combination of piston and cylinder.

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(6) (7)

Seal washer Washer

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Cylinder Block MECHANICAL

B: INSTALLATION (6)

(5)

(4)

(1)

(7)

(3)

(3)

(7) (6)

(2)

(7) (6)

ME-03186

(1) (2) (3)

Crankshaft bearing Crankshaft Cylinder block

(4) (5)

Rear oil seal O-ring

1) Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal. 2) Position the crankshaft and O-ring on cylinder block RH.

(6) (7)

Seal washer Washer

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

NOTE: Use new O-rings. 3) Apply liquid gasket to the mating surfaces of cylinder block RH, and position cylinder block LH. NOTE: • Install within 5 min. after applying liquid gasket. • Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.

ME-00145

4) Apply a coat of engine oil to the washer and bolt thread. NOTE: Use a new seal washer.

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Cylinder Block MECHANICAL

5) Tighten the 10 mm cylinder block connecting bolts on the LH side (A — D) in alphabetical order.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb) (G)

(E)

(I)

(F)

(J)

(A) (D) (H) ME-00841

(B) (C) ME-00840

6) Tighten the 10 mm cylinder block connecting bolts on RH side (E — J) in alphabetical sequence.

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb)

9) Tighten the LH side cylinder block connecting bolts (A — D) further in alphabetical order. • (A), (C): Angle tightening

Tightening angle: 90° • (B), (D): Torque tightening Tightening torque: 40 N·m (4.1 kgf-m, 29.5 ft-lb)

(G)

(E)

(J) (A) (D)

(I)

(H) (F) (B)

ME-00841

(C)

7) Tighten the LH side cylinder block connecting bolts (A — D) further in alphabetical order.

ME-00840

10) Tighten the RH side cylinder block connecting bolts (E — J) further in alphabetical order.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

Tightening angle: 90° (A) (D) (G)

(E)

(I)

(F)

(J)

(B) (C) ME-00840

8) Tighten the RH side cylinder block connecting bolts (E — J) further in alphabetical order.

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(H) ME-00841

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Cylinder Block MECHANICAL

11) Tighten the 8 mm and 6 mm cylinder block connecting bolts on the LH side (A — H) in alphabetical order.

15) Position the upper rail gap at (C) in the figure.

(C)

Tightening torque: (A) — (G): 25 N·m (2.5 kgf-m, 18.4 ft-lb) (H): 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

25 25

(G)

(C) (C)

(E)

(A)

(B)

LH

RH

ME-02722

16) Align the upper rail spin stopper (E) to the side hole (D) on the piston. (D) (D)

(E)

(F)

(H)

ME-00147

12) Apply a coat of engine oil to the oil seal periphery and install the rear oil seal using ST1 and ST2. NOTE: Use a new rear oil seal. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER (B)

ME-02471

17) Position the expander gap at (F) in the figure on the 180° opposite direction of (C).

(A)

ST2

180 (C)

(F)

(C)

(F)

180

ST1

RH

ME-00148

LH ME-02723

(A) Rear oil seal (B) Flywheel attaching bolt

18) Set the lower rail gap at position (G), located 120° clockwise from (C).

13) Position the top ring gap at (A) or (B) in the figure. 14) Position the second ring gap at 180° on the reverse side the top ring gap. 180

120 (G) (C)

180

(C) (G) 120 RH (B)

(A)

RH

(A)

LH ME-02724

(B)

LH ME-02721

NOTE: • Make sure ring gaps do not face the same direction. • Make sure ring gaps are not within the piston skirt area.

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19) Install the snap ring. Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block, and the piston pin hole on the opposite side. NOTE: Use new snap rings. #3

#1

#4

(A)

#2

ME-00306

(A) Front side (5)

T

(4) (1)

(5)

(3)

(4) (3)

(2)

(2)

(1)

ME-02442

(1) (2) (3)

Piston Piston pin Snap ring

(4) (5)

Gasket Service hole plug

ME(H4SO)-76

Tightening torque:N·m (kgf-m, ft-lb) T: 70 (7.1, 51.6)

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20) Install the piston. (1) Set the parts so that the #1 and #2 cylinders are on the upper side. (2) Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET (3) Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE

(3) Apply a coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole. (4) Install the snap ring. NOTE: Use new snap rings.

ST1

ME-00159

(5) Apply liquid gasket to the threaded portion of the service hole plug. ST2 ME-00157

NOTE: Face the piston front mark towards the front of the engine.

RH

Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent

ME-00160

(A)

LH ME-02725

(A) Front mark

21) Install the piston pin. (1) Apply a thin coat of engine oil to ST3. (2) Insert ST3 into the service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE ST1

ST3

ME-00158

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(6) Install the service hole plug and gasket. NOTE: Use a new gasket.

Tightening torque: 70 N·m (7.1 kgf-m, 51.6 ft-lb)

ME-00140 (5)

T2

T1 (6)

(4)

(3)

(7)

(2) (1)

(3) (2)

(1) ME-02440

(1) (2) (3) (4)

Piston Piston pin Snap ring Gasket

(5) (6) (7)

Service hole plug Service hole cover O-ring

ME(H4SO)-78

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 70 (7.1, 51.6)

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Cylinder Block MECHANICAL

(7) Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins. (8) Install the service hole cover. NOTE: Use new O-rings.

• Before installing the cylinder block lower, clean the mating surface of cylinder block lower and cylinder block. • Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 22) Install the water pipe assembly.

(A)

NOTE: Use new O-rings.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) LU-02581

(A) O-ring

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb) ME-00300

23) Install the baffle plate. NOTE: • Use a new seal. • Make sure that the seals (A) are installed securely on the baffle plate in a direction as shown in the figure below.

T2

T1 ME-04327

(A)

25) Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan. NOTE: • Before installing the oil pan, clean the mating surface of oil pan and cylinder block. • Install within 5 min. after applying liquid gasket. LU-00052

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 24) Apply liquid gasket to the mating surfaces of cylinder block lower, and install the cylinder block lower.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

CAUTION: Be careful not to apply any liquid gasket to the O-ring attachment section. NOTE: • Use new O-rings.

LU-02580

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Cylinder Block MECHANICAL

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

NOTE: Use a new front oil seal.

ST

LU-02583

26) Apply liquid gasket to the mating surfaces of the oil separator cover and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover. NOTE: • Install within 5 min. after applying liquid gasket. • Use new oil separator cover.

LU-00021

(2) Apply liquid gasket to the mating surfaces of oil pump. NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

Liquid gasket: • Mating surface THREE BOND 1217G (Part No. K0877Y0100) or equivalent • (A) bolt threads (when reusing bolts) THREE BOND 1324 (Part No. 004403042) or equivalent

(A)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

ME-00165

(A)

(A) O-ring

(3) Apply a coat of engine oil to the inside of oil seal.

ME-03333

27) Install the drive plate. 28) Install the oil pump. (1) Using the ST, install the front oil seal. ST 499587100 OIL SEAL INSTALLER

ME-00312

(4) Install the oil pump to cylinder block. CAUTION: • Be careful not to damage the front oil seal during installation. • Make sure the front oil seal lip is not folded. NOTE: • Align the flat surface of oil pump’s inner rotor with that of crankshaft before installation. • Use new O-rings.

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• Do not forget to assemble O-rings. (5) Apply liquid gasket to the three bolts thread shown in figure. (when reusing bolts)

Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: T: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

T

35) Install the timing belt. 36) Adjust the valve clearance. 37) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. (2) Temporarily tighten the rocker cover bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order in two steps.

LU-02103

29) Install the water pump and gasket.

Tightening torque: 1st 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 2nd (only (a) and (b) are tightened) 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) RH side (f)

NOTE: • When installing the water pump, tighten bolts in two stages in alphabetical order as shown in the figure. • Use a new gasket.

Tightening torque: First: 12 N·m (1.2 kgf-m, 8.9 ft-lb) Second: 12 N·m (1.2 kgf-m, 8.9 ft-lb)

(d)

(B)

(a)

(b)

(c)

(e)

ME-02715

LH side

(C) (A)

(f)

(D)

(E)

(a)

(c)

(F)

ME-04425

30) Install the water by-pass pipe for heater.

(d)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 31) Install the oil filter.

32) Install the cylinder head. 33) Install the generator and A/C compressor with their brackets.

(b)

(e)

ME-02716

38) Install the timing belt cover. 39) Install the crank pulley. 40) Install the intake manifold. 41) Install the V-belts.

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb) 34) Install the crank sprocket.

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C: DISASSEMBLY (1) (2)

(2)

(7)

(5) (4)

(3) (6)

ME-03562

(1) (2) (3)

Connecting rod cap Connecting rod bearing Top ring

(4) (5)

Second ring Oil ring

1) Remove the connecting rod cap. 2) Remove the connecting rod bearing. NOTE: Keep the removed connecting rods, connecting rod caps and bearings in order so that they are kept in their original combinations/groups, and not mixed together. 3) Remove the piston rings using piston ring expander. 4) Remove the oil ring by hand. NOTE: Arrange the removed piston rings in proper order, to prevent confusion. 5) Remove the snap ring.

ME(H4SO)-82

(6) (7)

Snap ring Connecting rod

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Cylinder Block MECHANICAL

D: ASSEMBLY (3) T

(1)

(1) (2)

(4) (5)

(6)

(8)

(7) ME-03154

(1) (2) (3) (4)

Connecting rod bearing Connecting rod Connecting rod cap Oil ring

(5) (6) (7) (8)

Second ring Top ring Snap ring Side mark

1) Apply engine oil to the surface of the connecting rod bearings, and install the connecting rod bearings onto connecting rods and connecting rod caps. 2) Position each connecting rod with the side with a side mark facing forward, and install it. 3) Attach the connecting rod cap, and tighten with connecting rod nut. Make sure the arrow on connecting rod cap faces the front during installation. NOTE: • Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. • When tightening the connecting rod nuts, apply oil on the threads.

Tightening torque: 45 N·m (4.6 kgf-m, 33.2 ft-lb) 4) Install the oil ring upper rail, expander and lower rail by hand. 5) Install the second ring and top ring using piston ring expander.

Tightening torque:N·m (kgf-m, ft-lb) T: 45 (4.6, 33.2)

E: INSPECTION 1. CYLINDER BLOCK 1) Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Check the oil passages for clogging. 3) Inspect the cylinder head surface that mates with cylinder block for warping by using a straight edge, and correct by grinding if necessary.

Warping limit: 0.025 mm (0.00098 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)

NOTE: Assemble so that the piston ring mark “R” faces the top side of the piston.

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Cylinder Block MECHANICAL

2. CYLINDER AND PISTON 1) The cylinder bore size is stamped on the front upper face of the cylinder block.

Out-of-roundness: Standard 0.010 mm (0.0004 in)

NOTE: • Measurement should be performed at a temperature of 20°C (68°F). • Standard sized pistons are classified into two grades, “A” and “B”. These grades should be used as guide lines in selecting a standard piston.

(A)

(B)

Standard diameter: A: 99.505 — 99.515 mm (3.9175 — 3.9179 in) B: 99.495 — 99.505 mm (3.9171 — 3.9175 in)

H1 H2 H3 H4

(B)

#5

4

5

ME-00171

#4

5

4

(A)

(A) (B) H1 H2 H3 H4

A

A

#1

B

#2

(F)

B

#3 (D)

(E) (C) ME-00170

(A) (B) (C) (D) (E) (F)

Main journal size mark Cylinder block (RH) — (LH) combination mark #1 cylinder bore size mark #2 cylinder bore size mark #3 cylinder bore size mark #4 cylinder bore size mark

2) Measure inner diameter of each cylinder. Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F).

Taper: Standard 0.015 mm (0.0006 in)

Piston pin direction Thrust direction 10 mm (0.39 in) 45 mm (1.77 in) 80 mm (3.15 in) 115 mm (4.53 in)

3) When the piston is to be replaced due to general or cylinder wear, select a suitable sized piston by measuring the piston clearance. 4) Measure outer diameter of each piston. Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20°C (68°F).

Piston grade point H: 38.2 mm (1.504 in) Piston outer diameter: Standard A: 99.510 — 99.520 mm (3.9177 — 3.9181 in) B: 99.500 — 99.510 mm (3.9173 — 3.9177 in) 0.25 mm (0.0098 in) oversize: 99.750 — 99.770 mm (3.9272 — 3.9280 in)

0.50 mm (0.0197 in) oversize: 100,000 — 100.020 mm (3.9370 — 3.9378 in)

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Cylinder Block MECHANICAL

3. PISTON AND PISTON PIN 1) Check the piston and piston pin for damage, cracks or wear. Replace if faulty. 2) Check the piston ring groove for wear or damage. Replace if faulty. 3) Make sure the piston pin can be inserted into the piston pin hole by a thumb at 20°C (68°F). Replace if faulty.

H ME-00172

5) Calculate the clearance between cylinder and piston.

Clearance between piston pin hole and piston pin: Standard 0.004 — 0.008 mm (0.0002 — 0.0003 in)

NOTE: Measurement should be performed at a temperature of 20°C (68°F).

Cylinder to piston clearance at 20°C (68°F): Standard –0.015 — 0.005 mm (–0.00059 — 0.00020 in) 6) Boring and honing (1) If any of the measured value of taper, out-ofroundness or cylinder-to-piston clearance is out of standard or if there is any damage on the cylinder wall, rebore it to replace with an oversize piston.

ME-00173

CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and replaced with oversize pistons. (2) If the cylinder inner diameter exceeds the limit after boring and honing, replace the cylinder block. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, when measuring the cylinder diameter, wait until it has cooled to room temperature.

ME-00174

4) Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.

Cylinder inner diameter boring limit To 100.005 mm (3.9372 in) (A)

ME-00175

5) Check the piston pin snap ring for distortion, cracks and wear.

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Cylinder Block MECHANICAL

4. PISTON RING 1) If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of the same size as piston. NOTE: • The top ring and second ring have the mark to determine the direction for installing. When attaching the ring to the piston, face these marks towards the top side. • Oil ring consists of the upper rail, expander and lower rail. When attaching the oil ring to the piston, pay attention to the direction of each rail.

2) Using the piston, insert the piston ring and oil ring into the cylinder so that they are perpendicular to the cylinder wall, and measure the piston ring gap with a thickness gauge.

Top ring Piston ring gap

Standard mm (in) 0.20 — 0.35 (0.0079 — 0.0138)

Second ring

0.37 — 0.52 (0.0146 — 0.0205)

Oil ring rail

0.20 — 0.50 (0.0079 — 0.0197)

(A) (B) (C)

ME-00177

3) Fit the piston ring straight into the piston ring groove, then measure the clearance between piston ring and piston ring groove with a thickness gauge.

(A)

(B)

NOTE: Before measuring the clearance, clean the piston ring groove and piston ring.

(C)

Standard mm (in) ME-02480

(A) Upper rail (B) Expander (C) Lower rail

Clearance between piston ring and piston ring groove

Top ring

0.040 — 0.080 (0.0016 — 0.0031)

Second ring

0.030 — 0.070 (0.0012 — 0.0028)

ME-00178

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Cylinder Block MECHANICAL

5. CONNECTING ROD 1) Replace the connecting rod, if the large or small end thrust surface is damaged. 2) Check for bend or twist using a connecting rod aligner. Replace the connecting rod if the bend or twist exceeds the limit.

Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in) (A)

(B)

5) Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary.

Connecting rod oil clearance: Standard 0.016 — 0.044 mm (0.0006 — 0.0017 in) Unit: mm (in) Bearing

Bearing size (Thickness at center)

Outer diameter of crank pin

Standard

1.492 — 1.501 (0.0587 — 0.0591)

51.984 — 52.000 (2.0466 — 2.0472)

1.510 — 1.513 (0.0594 — 0.0596)

51.954 — 51.970 (2.0454 — 2.0461)

1.520 — 1.523 (0.0598 — 0.0600)

51.934 — 51.950 (2.0446 — 2.0453)

1.620 — 1.623 (0.0638 — 0.0639)

51.734 — 51.750 (2.0368 — 2.0374)

0.03 (0.0012) Undersize 0.05 (0.0020) Undersize 0.25 (0.0098) Undersize

6) Inspect the bushing at connecting rod small end, and replace with a new part if worn or damaged. 7) Measure the piston pin clearance at connecting rod small end. Replace it with a new part if the value is not within the standard,

(A)

(B)

ME-00179

(A) Thickness gauge (B) Connecting rod

Clearance between piston pin and bushing: Standard 0 — 0.022 mm (0 — 0.0009 in)

3) Install the connecting rod with bearings attached to the crankshaft, and using a thickness gauge, measure the thrust clearance. If the thrust clearance exceeds the standard or uneven wear is found, replace the connecting rod.

Connecting rod thrust clearance: Standard 0.070 — 0.330 mm (0.0028 — 0.0130 in)

ME-00181

ME-00174

ME-00180

4) Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.

8) The replacement procedure for the connecting rod small end bushing is as follows.

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Cylinder Block MECHANICAL

(1) Remove the bushing from connecting rod with ST and press. (2) Press the bushing with the ST after applying oil on the periphery of new bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER

3) Inspect the crank journal and crank pin for wear. If they are not within the standard, replace the bearing with a suitable (undersize) one, and replace or grind to correct the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used.

Crank pin Out-of-roundness 0.003 mm (0.0001 in) Cylindricality 0.004 mm (0.0002 in) Grinding limit (dia.) To 51.750 mm (2.0374 in)

ST

ME-00182

(3) Make two 3 mm (0.12 in) holes in the pressed bushing to match the pre-manufactured holes on the connecting rod, then ream the inside of the bushing. (4) After completion of reaming, clean the bushing to remove chips.

Crank journal Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit (dia.) To 59.758 mm (2.3527 in)

6. CRANKSHAFT AND CRANKSHAFT BEARING 1) Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. If defective, replace the crankshaft. 2) Measure warping of the crankshaft. If it exceeds the limit, correct or replace it. NOTE: If a suitable V-block is not available, using just the #1 and #5 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge.

Crankshaft bend limit: 0.035 mm (0.0014 in)

ME-00183

ME(H4SO)-88

ME-00184

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Cylinder Block MECHANICAL Unit: mm (in) Crank journal outer diameter #2, #4, #5 59.992 — 60.008 (2.3619 — 2.3625) 2.000 — 2.013 (0.0787 — 0.0793)

59.962 — 59.978 (2.3607 — 2.3613) 2.017 — 2.020 (0.0794 — 0.0795)

59.962 — 59.978 (2.3607 — 2.3613) 2.019 — 2.022 (0.0795 — 0.0796)

51.954 — 51.970 (2.0454 — 2.0461) 1.510 — 1.513 (0.0594 — 0.0596)

Journal O.D.

59.942 — 59.958 (2.3599 — 2.3605)

59.942 — 59.958 (2.3599 — 2.3605)

51.934 — 51.950 (2.0446 — 2.0453)

Bearing size (Thickness at center)

2.027 — 2.030 (0.0798 — 0.0799)

2.029 — 2.032 (0.0799 — 0.0800)

1.520 — 1.523 (0.0598 — 0.0600)

59.742 — 59.758 (2.3520 — 2.3527) 2.127 — 2.130 (0.0837 — 0.0839)

59.742 — 59.758 (2.3520 — 2.3527) 2.129 — 2.132 (0.0838 — 0.0839)

51.734 — 51.750 (2.0368 — 2.0374) 1.620 — 1.623 (0.0638 — 0.0639)

Journal O.D. Standard

0.03 (0.0012) Undersize

0.05 (0.0020) Undersize

0.25 (0.0098) Undersize

Crank pin outer diameter

#1, #3 59.992 — 60.008 (2.3619 — 2.3625) 1.998 — 2.011 (0.0787 — 0.0792)

Bearing size (Thickness at center) Journal O.D. Bearing size (Thickness at center)

Journal O.D. Bearing size (Thickness at center)

4) Use a thickness gauge to measure the thrust clearance of crankshaft at #5 crank journal bearing. If clearance exceeds the standard, replace the bearing.

Crankshaft thrust clearance: Standard 0.030 — 0.115 mm (0.0012 — 0.0045 in)

ME-00322

5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear. 6) Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or grind to correct the crankshaft as necessary.

Crankshaft oil clearance: Standard 0.010 — 0.030 mm (0.0004 — 0.0012 in)

ME(H4SO)-89

51.984 — 52.000 (2.0466 — 2.0472) 1.492 — 1.501 (0.0587 — 0.0591)

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Oil Switching Solenoid Valve MECHANICAL

22.Oil Switching Solenoid Valve A: REMOVAL

9) Remove the oil switching solenoid valve holder from the cylinder head. (A)

(C)

(B)

1. RH SIDE 1) Disconnect the ground cable from battery.

(D) (E)

ME-02726

(A) (B) (C) (D) (E)

IG-02107

2) Remove the air intake boot assembly. 3) Remove the bolt, and disconnect the bulkhead harness connector from the engine harness connector and rear engine hanger.

2. LH SIDE 1) Disconnect the ground cable from battery.

FU-05129

4) Slide the engine harness connector in the direction of the arrow and remove it from the rear engine hanger.

FU-05130

5) Disconnect the connector from the oil switching solenoid valve. 6) Remove the oil switching solenoid valve. 7) Remove the variable valve lift diagnosis oil pressure switch. 8) Remove the oil temperature sensor.

Oil switching solenoid valve Variable valve lift diagnosis oil pressure switch Oil temperature sensor Oil switching solenoid valve holder Gasket

IG-02107

2) Remove the V-belts. 3) Remove the crank pulley. 4) Remove the timing belt cover. 5) Remove the timing belt. 6) Remove the cam sprocket. 7) Remove the timing belt cover No. 2 LH. 8) Disconnect the connector from the oil switching solenoid valve. 9) Remove the oil switching solenoid valve. 10) Remove the variable valve lift diagnosis oil pressure switch.

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Oil Switching Solenoid Valve MECHANICAL

11) Remove the oil switching solenoid valve holder from the cylinder head.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(B)

(D) (C) (A)

(A) (B) (C) (D)

FU-05129

ME-02727

Oil switching solenoid valve Variable valve lift diagnosis oil pressure switch Oil switching solenoid valve holder Gasket

B: INSTALLATION 1. RH SIDE Install in the reverse order of removal. NOTE: • Use a new gasket. • Apply liquid gasket to variable valve lift diagnosis oil pressure switch threads. • Install the oil switching solenoid valve to the holder, then install it to the cylinder head.

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 10 N·m (1.0 kgf-m, 7.4 ft-lb) T3: 17 N·m (1.7 kgf-m, 12.5 ft-lb) T4: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

2. LH SIDE Install in the reverse order of removal. NOTE: • Use a new gasket. • Apply liquid gasket to variable valve lift diagnosis oil pressure switch threads. • Install the oil switching solenoid valve to the holder, then install it to the cylinder head.

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 10 N·m (1.0 kgf-m, 7.4 ft-lb) T3: 17 N·m (1.7 kgf-m, 12.5 ft-lb) Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent (B) T3

Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent T1

(A)

(C)

T2 (C) (A)

T4 (B)

T2

(A) (B) (C) (D)

T3

(D) (E) ME-03002

(A) (B) (C) (D) (E)

(D)

Oil switching solenoid valve Variable valve lift diagnosis oil pressure switch Oil temperature sensor Oil switching solenoid valve holder Gasket

ME(H4SO)-91

T1

ME-03003

Oil switching solenoid valve Variable valve lift diagnosis oil pressure switch Oil switching solenoid valve holder Gasket

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Intake and Exhaust Valve MECHANICAL

23.Intake and Exhaust Valve A: SPECIFICATION Refer to “Cylinder Head” for removal and installation procedures of the intake and exhaust valves.

ME(H4SO)-92

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Piston MECHANICAL

24.Piston A: SPECIFICATION Refer to “Cylinder Block” for removal and installation procedures of pistons.

ME(H4SO)-93

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Connecting Rod MECHANICAL

25.Connecting Rod A: SPECIFICATION Refer to “Cylinder Block” for removal and installation procedures of connecting rods.

ME(H4SO)-94

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Crankshaft MECHANICAL

26.Crankshaft A: SPECIFICATION Refer to “Cylinder Block” for removal and installation procedures of the crankshaft.

ME(H4SO)-95

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Engine Trouble in General MECHANICAL

27.Engine Trouble in General A: INSPECTION NOTE: The “RANK” shown in the chart shows the possibilities of the cause of trouble in order from “Very often” to “Rarely”. A — Very often B — Sometimes C — Rarely Symptoms 1. Engine does not start. 1) Starter does not turn.

2) Initial combustion does not occur.

Problem parts etc. Starter

Possible cause

Defective battery-to-starter harness Defective starter switch Defective inhibitor switch Defective starter Battery Improper connection of terminal Run-down battery Defective charging system Friction Seizure of crankshaft and connecting rod bearing Seized camshaft Seized or stuck piston and cylinder Immobilizer system Starter Defective starter Engine control system Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity)

ME(H4SO)-96

RANK B C C B A A B C C C A C A A C B B B C C C C C B C B B

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Engine Trouble in General MECHANICAL Symptoms 3) Initial combustion occurs.

4) Engine stalls after initial combustion.

Problem parts etc. Possible cause Engine control system Intake system Defective intake manifold gasket Defective throttle body gasket Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element Fuel line Clogged fuel line Lack of fuel or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity)

ME(H4SO)-97

RANK A B B C C B B B C C C C C B C B B A B C C B B C C B B B C C C C C B C B B

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Engine Trouble in General MECHANICAL Symptoms 2. Rough idle and engine stall

Problem parts etc. Possible cause Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Defective rocker cover gasket Cooling system Over-heating Others Evaporative emission control system malfunction Stuck or damaged throttle valve

ME(H4SO)-98

RANK A A A A B B C B C C C B C B B B B C B B A B B C C A B

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Engine Trouble in General MECHANICAL Symptoms 3. Low output, hesitation and poor acceleration

Problem parts etc. Possible cause Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Cooling system Over-heating Over-cooling Others Evaporative emission control system malfunction

ME(H4SO)-99

RANK A A A B B B B B A B B C B B B B B C B C A B B C C A

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Engine Trouble in General MECHANICAL Symptoms 4. Surging

5. Engine does not return to idle. 6. Dieseling (Run-on)

7. After burning in exhaust system

Problem parts etc. Possible cause Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Cooling system Over-heating Others Evaporative emission control system malfunction Engine control system Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve Engine control system Cooling system Over-heating Others Evaporative emission control system malfunction Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective PCV valve Loosened oil filler cap Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over-cooling Others Evaporative emission control system malfunction

ME(H4SO)-100

RANK A A A A B B B B B B B C B B C C C C C C A B B C A A A A B B A C C B B C B B C C B C C C A C C C

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Engine Trouble in General MECHANICAL Symptoms 8. Knocking

Problem parts etc. Possible cause Engine control system Intake system Loosened oil filler cap Timing belt Defective timing Compression Incorrect valve clearance Incorrect valve timing Cooling system Over-heating 9. Excessive engine oil con- Intake system Loosened or cracked PCV hose sumption Defective PCV valve Loosened oil filler cap Compression Defective valve stem Worn or stuck piston rings, cylinder and piston Lubrication system Loosened oil pump attaching bolts and defective gasket Defective oil filter gasket Defective crankshaft oil seal Defective rocker cover gasket Loosened oil drain plug or defective gasket Loosened oil pan fitting bolts or defective oil pan 10. Excessive fuel consump- Engine control system tion Intake system Dirty air cleaner element Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Lubrication system Cooling system

Incorrect valve timing Incorrect oil pressure Over-cooling

ME(H4SO)-101

RANK A B B C B A A B C A A B B B B B B A A B B C C B C C B B C C

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Engine Noise MECHANICAL

28.Engine Noise A: INSPECTION Type of sound

Regular clicking sound

Condition Sound increases as engine speed increases.

Oil pressure is low. Heavy and dull clank Oil pressure is normal.

Possible cause • • • • • • • • •

Valve mechanism is defective. Incorrect valve clearance Worn valve rocker Worn camshaft Broken valve spring Worn crankshaft main bearing Worn connecting rod bearing (large end) Damaged engine mounting Loosened flywheel mounting bolt

• • • •

Ignition timing advanced Accumulation of carbon inside combustion chamber Wrong heat range of spark plug Improper octane value gasoline

High-pitched clank (Spark knock)

Sound is noticeable when accelerating with an overload condition.

Clank when engine speed is 1,000 to 2,000 rpm

Sound is reduced when fuel • Worn crankshaft main bearing injector connector of noisy cyl- • Worn connecting rod bearing (large end) inder is disconnected. *

Knocking sound when engine is operating under idling speed and engine is warm

Sound is reduced when fuel • Worn cylinder liner and piston ring injector connector of noisy cyl- • Broken or stuck piston ring inder is disconnected. * • Worn piston pin and hole at piston end of connecting rod Sound is not reduced if each • Worn cam sprocket fuel injector connector is dis• Worn camshaft journal bore in cylinder head connected in turn. *

Squeaky sound Rubbing sound Gear scream when starting engine

— —

Insufficient generator lubrication Poor contact of generator brush and rotor



• Defective ignition starter switch • Worn gear and starter pinion

Sound like polishing glass with a dry cloth



• Loose V-belt • Defective water pump shaft

Hissing sound



Timing belt noise



Valve noise



• Insufficient compression • Air leakage in air intake system, hose, connection or manifold • Loose timing belt • Timing belt contacting with adjacent part Incorrect valve clearance

* When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory. Therefore, perform the Clear Memory Mode and Inspection Mode after connecting the fuel injector connector.

ME(H4SO)-102

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EXHAUST

EX(H4SO) 1. 2. 3. 4. 5.

Page General Description ...................................................................................2 Front Exhaust Pipe .....................................................................................4 Center Exhaust Pipe ..................................................................................7 Rear Exhaust Pipe .....................................................................................8 Muffler ........................................................................................................9

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General Description EXHAUST

1. General Description A: COMPONENT

(5)

(30)

(8)

T1

(6) (7) T8 (31)

(9) (2) (5) (6) (1)

(4)

T8

(3) T10 (11)

(18)

T3

T2

T9 (16)

(28)

(24)

(10) (23)

T3

(22) T2 (12)

(13) T2

(20) (14) (15)

(17) (19)

T2

T2

T7 (20)

(25)

T5 (32)

T5

T4 T2

T5 (21) (29)

T2 T6

(26) T2

(27)

T2

EX-02597

EX(H4SO)-2

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General Description EXHAUST (1) (2)

Gasket Spring

(16) (17)

Front oxygen (A/F) sensor Front catalytic converter

(31) (32)

(3) (4) (5)

Chamber Rear exhaust pipe Cushion rubber (without protrusion)

(18) (19) (20)

Rear oxygen sensor Gasket Gasket

Tightening torque:N·m (kgf-m, ft-lb) T1: 7.5 (0.8, 5.5)

(6) (7) (8)

Self-locking nut Gasket Muffler

(21) (22) (23)

(9)

BOLT

(24)

(10)

Center exhaust pipe front upper cover Rear catalytic converter upper cover

(25) (26)

Front exhaust pipe Front exhaust pipe upper cover LH Front exhaust pipe upper cover RH Front catalytic converter upper cover Front catalytic converter lower cover Front exhaust pipe lower cover RH

(12) (13)

Center exhaust pipe Rear catalytic converter

(27) (28)

Front exhaust pipe lower cover LH Band

(14)

Rear catalytic converter lower cover Center exhaust pipe front lower cover

(29)

Hanger bracket (CVT model)

(30)

Ornamental muffler tip (Models with ornamental muffler tips)

(11)

(15)

B: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. • If any fat adheres to the exhaust pipe, wipe it off. Otherwise a fire may happen.

EX(H4SO)-3

Cushion rubber (with protrusion) Hanger bracket (MT model)

T2: 13 (1.3, 9.6) T3: 18 (1.8, 13.3) T4: 23 (2.3, 17.0) T5: 30 (3.1, 22.1) T6: 35 (3.6, 25.8) T7: 40 (4.1, 29.5) T8: 48 (4.9, 35.4) T9: T10:

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Front Exhaust Pipe EXHAUST

2. Front Exhaust Pipe

CAUTION: Be careful not to drop the front exhaust pipe and center exhaust pipe assembly.

A: REMOVAL CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Remove the air intake duct. 2) Disconnect the ground cable from battery.

EX-02529

8) Remove the bolt which holds center exhaust pipe to hanger bracket.

IG-02107

3) Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B) and remove the clip (C) fastening the harness. EX-02530

9) Remove the front exhaust pipe and center exhaust pipe as a unit from the vehicle.

(B) (A)

(C)

EX-02527

4) Lift up the vehicle. 5) Remove the under cover. 6) Disconnect the center exhaust pipe from rear exhaust pipe.

CAUTION: • The front exhaust pipe and center exhaust pipe assembly are very heavy. Be careful not to drop the exhaust pipes when removing. • After removing the front exhaust pipe and center exhaust pipe assembly, do not pull the rear exhaust pipe with excessive force. 10) Remove the front exhaust pipe from the center exhaust pipe.

EX-02124

EX-02528

7) Remove the nuts which hold front exhaust pipe onto cylinder heads.

11) Remove the front oxygen (A/F) sensor and rear oxygen sensor from the front exhaust pipe.

EX(H4SO)-4

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Front Exhaust Pipe EXHAUST

B: INSTALLATION 1) Install the front oxygen (A/F) sensor and rear oxygen sensor to the front exhaust pipe. 2) Install the front exhaust pipe to the center exhaust pipe.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

NOTE: Use a new gasket.

Tightening torque: 40 N·m (4.1 kgf-m, 29.5 ft-lb)

EX-02528

6) Tighten the bolts which hold center exhaust pipe to hanger bracket.

Tightening torque: 35 N·m (3.6 kgf-m, 25.8 ft-lb)

EX-02124

3) Install the front exhaust pipe and center exhaust pipe as a unit to the vehicle. NOTE: Use a new gasket. 4) Temporarily tighten the nuts which hold front exhaust pipe to cylinder heads.

EX-02530

7) Tighten the nuts which hold front exhaust pipe to cylinder heads.

Tightening torque: 30 N·m (3.1 kgf-m, 22.1 ft-lb)

EX-02529

5) Install the center exhaust pipe to rear exhaust pipe. NOTE: Use a new gasket.

EX-02529

8) Install the under cover. 9) Lower the vehicle.

EX(H4SO)-5

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Front Exhaust Pipe EXHAUST

10) Connect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B), and fasten the harness with the clip (C).

(B) (A)

(C)

EX-02527

11) Connect the ground cable to battery.

IG-02107

12) Install the air intake duct.

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting.

EX(H4SO)-6

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Center Exhaust Pipe EXHAUST

3. Center Exhaust Pipe A: REMOVAL After removing the center exhaust pipe and front exhaust pipe as a unit, separate them. Refer to “Front Exhaust Pipe” for the removal procedure.

B: INSTALLATION Install the center exhaust pipe and front exhaust pipe as a unit. Refer to “Front Exhaust Pipe” for the installation procedure.

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting.

EX(H4SO)-7

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Rear Exhaust Pipe EXHAUST

4. Rear Exhaust Pipe A: REMOVAL CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Lift up the vehicle. 2) Remove the rear exhaust pipe from center exhaust pipe.

NOTE: After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.

EX-02598

3) Install the rear exhaust pipe to the muffler. NOTE: Use a new gasket and self-locking nut. EX-02528

Tightening torque: 48 N·m (4.9 kgf-m, 35.4 ft-lb)

3) Remove the rear exhaust pipe from the muffler. CAUTION: Be careful not to drop the rear exhaust pipe.

EX-02531

4) Install the rear exhaust pipe to center exhaust pipe. EX-02531

4) Apply a coat of spray type lubricant to the mating area of cushion rubber. 5) Remove the rear exhaust pipe from the cushion rubber.

NOTE: Use a new gasket.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

EX-02528 EX-02598

5) Lower the vehicle.

B: INSTALLATION

C: INSPECTION

1) Apply a coat of spray type lubricant to the mating area of cushion rubber. 2) Install the rear exhaust pipe to the cushion rubber.

1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting. 3) Check the cushion rubber for wear or crack.

EX(H4SO)-8

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Muffler EXHAUST

5. Muffler

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Lift up the vehicle. 2) Remove the muffler from rear exhaust pipe.

NOTE: • Use a new gasket and self-locking nut. • After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.

Tightening torque: 48 N·m (4.9 kgf-m, 35.4 ft-lb)

EX-02531

3) Apply a coat of spray type lubricant to the mating area of cushion rubber. 4) Remove the muffler from the cushion rubber. CAUTION: Be careful not to drop the muffler during removal.

EX-02531

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting. 3) Check the cushion rubber for wear or crack.

EX-02532

EX(H4SO)-9

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Muffler EXHAUST

EX(H4SO)-10

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COOLING

CO(H4SO) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Page General Description ...................................................................................2 Radiator Fan System .................................................................................7 Engine Coolant .........................................................................................14 Water Pump .............................................................................................16 Thermostat ...............................................................................................18 Radiator ....................................................................................................20 Radiator Cap ............................................................................................23 Radiator Main Fan and Fan Motor ...........................................................24 Radiator Sub Fan and Fan Motor .............................................................25 Reservoir Tank .........................................................................................26 Engine Cooling System Trouble in General .............................................27

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General Description COOLING

1. General Description A: SPECIFICATION Electric fan + Forced engine coolant circulation system

Cooling system Total engine coolant capacity

2 (US qt, Imp qt)

Approx. 6.5 (6.9, 5.7)

Type

Centrifugal impeller type 200 (52.8, 44.0) 6,000 rpm — 225.4 kPa (23 mAq) 80°C (176°F) 76 (2.99) 8 60 (2.36)

Discharge rate 2 (US gal, Imp gal) /min. Pump speed — Discharge pressure Engine coolant temperature Impeller diameter mm (in) Number of impeller vanes Pump pulley diameter mm (in) Clearance between impeller and mm (in) Standard case Type Starting temperature to open Fully opens Valve lift mm (in) Valve bore mm (in) Discharge performance

Water pump

Thermostat

Radiator fan

Motor input

Main fan Sub fan

Fan diameter / Blade

Main fan Sub fan

0.5 — 1.5 (0.020 — 0.060) Wax pellet type 86 — 90°C (187 — 194°F) 95°C (203°F) 9.0 (0.354) or more 35 (1.38)

W W

90 90 300 mm (11.81 in)/4 300 mm (11.81 in)/5 Down flow, pressure type

Type Core dimensions Radiator

Pressure range in which cap valve is open

Width × Height × Thickness

687.4 × 340 × 16 (27.06 × 13.39 × 0.63)

mm (in)

Standard Positive presService sure side kPa (kg/cm2, psi) limit

93 — 123 (0.95 — 1.25, 14 — 18) 83 (0.85, 12)

Negative Standard pressure side

–1.0 to –4.9 or less (–0.01 — –0.05, –0.1 — –0.7) Corrugated fin type

Fins Reservoir tank

Capacity

Coolant Water for dilution Cooling system protecting agent

2 (US qt, Imp qt)

Recommended materials SUBARU Super Coolant (Concentrated type) SUBARU Super Coolant (Diluted type)

0.45 (0.48, 0.40)

Item number

Alternative

— — K0670Y0001

Distilled water



Soft water or tap water

Cooling system conditioner

SOA345001



CO(H4SO)-2

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General Description COOLING

B: COMPONENT 1. WATER PUMP

(2)

(1)

T1

(7) (3)

T1

(4)

(7)

(5)

T2

(6)

CO-02648

(1) (2) (3) (4)

Water pump ASSY Gasket Heater by-pass hose Thermostat

(5) (6) (7)

Gasket Thermostat cover Clip

CO(H4SO)-3

Tightening torque:N·m (kgf-m, ft-lb) T1: First 12 (1.2, 8.9) Second 12 (1.2, 8.9) T2: 12 (1.2, 8.9)

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General Description COOLING

2. RADIATOR & RADIATOR FAN (5) (8)

(6)

(5) T2

T1

T2

(7)

T1 (10)

T3

(9) (4)

(11)

(3) (20)

(12)

(2) (13)

(5)

B

B

(14)

(14)

A (17)

(19)

(16)

A

(14)

(1) (5)

(18) (15)

CO-02663

(1) (2)

Radiator lower cushion Radiator

(10) (11)

Radiator sub fan shroud Radiator sub fan, radiator sub fan motor ASSY

(3)

Radiator upper cushion

(12)

Radiator main fan shroud

(4)

Radiator upper bracket

(13)

Radiator main fan, radiator main fan motor ASSY

(5) (6) (7) (8) (9)

Clip Radiator inlet hose Engine coolant reservoir tank cap Over flow hose Engine coolant reservoir tank

(14) (15) (16) (17) (18)

CVTF hose clamp (CVT model) CVTF hose A (CVT model) CVTF hose B (CVT model) Radiator outlet hose Radiator drain plug

CO(H4SO)-4

(19) (20)

O-ring Radiator cap

Tightening torque:N·m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 7.5 (0.8, 5.5) T3: 12 (1.2, 8.9)

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General Description COOLING

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. • Prepare a container and cloth to prevent scattering of engine coolant when performing work where engine coolant can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing engine coolant.

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General Description COOLING

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 499977400

DESCRIPTION CRANK PULLEY WRENCH

REMARKS Used for removing and installing the crank pulley. (CVT model)

499977100

CRANK PULLEY WRENCH

Used for removing and installing the crank pulley. (MT model)

18231AA010

CAM SPROCKET WRENCH

Used for removing and installing cam sprocket. NOTE: CAM SPROCKET WRENCH (499207100) can also be used.

1B022XU0

SUBARU SELECT MONITOR III KIT

Used for troubleshooting the electrical system.

ST-499977400

ST-499977100

ST18231AA010

ST1B022XU0

2. GENERAL TOOL TOOL NAME Circuit tester Radiator cap tester

REMARKS Used for measuring resistance and voltage. Used for checking radiator and radiator cap.

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Radiator Fan System COOLING

2. Radiator Fan System A: WIRING DIAGRAM TO POWER SUPPLY CIRCUIT

MAIN FAN RELAY 1

13

FB-39 F/B FUSE NO. 22 (IG)

A/C SUB RELAY HOLDER FAN RELAY B497

MAIN FAN RELAY 2

3

J/C

B11

12 B482 B12

11 2

1

18

19

22

16

15

1

B473

10

21

20

MAIN FAN MOTOR

MB-7 M/B FUSE NO. 7 (B)

FB-35 F/B FUSE NO. 26 (IG)

17

2

14

MB-6 M/B FUSE NO. 8 (B)

B479 B : B135 ECM

SUB FAN MOTOR B473 B482

B497

B479

B: B135

1 2 3 4 5

2 1 8 10 11

3 4 5 6 9 7 12 13

14 15

16 17

1 2

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

18 19 20 21 22

A/C RELAY HOLDER

CO-02650

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Radiator Fan System COOLING

B: INSPECTION Operating condition: Radiator fan operates depending on the radiator fan operation mode related to engine coolant temperature or the radiator fan operation mode related to A/C compressor load, whichever is higher as an operation mode. • Radiator fan operation mode related to engine coolant temperature

(A) (1)

(2)

(3)

(4)

(5)(6)

(B)

(7)

CO-02661

(A)

Radiator fan operation mode

(B)

Engine coolant temperature

(1) (2) (3)

High-Speed Low-Speed OFF

(4) (5) (6)

96°C (205°F) 97.5°C (207°F) 98°C (208°F)

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(7)

100°C (212°F)

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Radiator Fan System COOLING

• Radiator fan operation mode related to A/C compressor load

(A) (1)

(2)

(3)

(4)

(5)

(6)

(B)

(7)

CO-02662

(A)

Radiator fan operation mode

(B)

A/C compressor refrigerant pressure

(1) (2) (3)

High-Speed Low-Speed OFF

(4) (5) (6)

0.8 MPa (8.16 kgf/cm2, 116 psi) 1.125 MPa (11.47 kgf/cm2, 163 psi) 1.25 MPa (12.75 kgf/cm2, 181 psi)

(7)

1.5 MPa (15.30 kgf/cm2, 218 psi)

DIAGNOSIS: Radiator main fan and radiator sub fans do not rotate under the above operating conditions. 1

2

Step CHECK OPERATION OF RADIATOR FAN. 1) Connect the delivery mode fuse. 2) Turn the ignition switch to ON. 3) Using the Subaru Select Monitor, check the forced operation of the radiator fan relay. NOTE: • When performing a forced operation radiator fan relay check using the Subaru Select Monitor, the radiator main fan and radiator sub fan will repeat low speed revolution → high speed revolution → OFF in this order. • Subaru Select Monitor For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. CHECK OPERATION OF RADIATOR FAN. 1) Connect the delivery mode fuse. 2) Turn the ignition switch to ON. 3) Using the Subaru Select Monitor, check the forced operation of the radiator fan relay. NOTE: • When performing a forced operation radiator fan relay check using the Subaru Select Monitor, the radiator main fan and radiator sub fan will repeat low speed revolution → high speed revolution → OFF in this order. • Subaru Select Monitor For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

Check Do the radiator main fans and radiator sub fans rotate at low speed?

Yes Go to step 2.

Do the radiator main fans and Radiator main fan radiator sub fans rotate at high system is normal. speed?

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No Go to step 3.

Go to step 27.

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Radiator Fan System COOLING

3

4

5

6

7

8

9

10

Step CHECK POWER SUPPLY TO SUB FAN RELAY. 1) Turn the ignition switch to OFF. 2) Remove the sub fan relay from A/C relay holder. 3) Measure the voltage between sub fan relay connector and chassis ground. Connector & terminal (B497) No. 10 (+) — Chassis ground (–): CHECK POWER SUPPLY TO SUB FAN RELAY. 1) Turn the ignition switch to ON. 2) Measure the voltage between sub fan relay connector and chassis ground. Connector & terminal (B497) No. 13 (+) — Chassis ground (–): CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 7. 3) Check the condition of fuse. CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 22. 3) Check the condition of fuse. CHECK SUB FAN RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between sub fan relay terminals. Terminals No. 10 — No. 11: CHECK SUB FAN RELAY. 1) Connect the battery to terminals No. 13 and No. 12 of the sub fan relay. 2) Measure the resistance between sub fan relay terminals. Terminals No. 10 — No. 11: CHECK HARNESS BETWEEN SUB FAN RELAY CONNECTOR AND SUB FAN MOTOR CONNECTOR. 1) Disconnect the connector from the sub fan motor. 2) Measure the resistance of harness between sub fan relay connector and sub fan motor connector. Connector & terminal (B482) No. 2 — (B497) No. 11: CHECK HARNESS BETWEEN SUB FAN MOTOR CONNECTOR AND MAIN FAN RELAY 2 CONNECTOR. 1) Remove the main fan relay 2 from A/C relay holder. 2) Measure the resistance of harness between sub fan motor connector and main fan relay 2 connector. Connector & terminal (B482) No. 1 — (B497) No. 18:

Check Is the voltage 10 V or more?

Yes Go to step 4.

No Go to step 5.

Is the voltage 10 V or more?

Go to step 7.

Go to step 6.

Is the fuse blown out?

Replace the fuse.

Repair the power supply line.

Is the fuse blown out?

Replace the fuse.

Repair the power supply line.

Is the resistance 1 MΩ or more?

Go to step 8.

Replace the sub fan relay.

Is the resistance less than 1 Ω? Go to step 9.

Replace the sub fan relay.

Is the resistance less than 1 Ω? Go to step 10.

Repair the open circuit of harness between sub fan relay connector and sub fan motor connector.

Is the resistance less than 1 Ω? Go to step 11.

Repair the open circuit of the harness between sub fan motor connector and main fan relay 2 connector.

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Radiator Fan System COOLING

11

12

13

14

15

16

17

18

19

Step Check Yes CHECK FOR POOR CONTACT. Is there poor contact of the sub Repair the poor Check poor contact of sub fan motor connector. fan motor connector? contact of sub fan motor connector. CHECK SUB FAN MOTOR. Does the radiator sub fan Go to step 13. Connect the battery positive (+) terminal to ter- rotate? minal No. 2 of the sub fan motor, and the ground (–) terminal to terminal No. 1. CHECK MAIN FAN RELAY 2. Is the resistance less than 1 Ω? Go to step 14. Measure the resistance between main fan relay 2 terminals. Terminals No. 21 — No. 18: CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Ω? Go to step 15. RELAY 2 CONNECTOR AND MAIN FAN MOTOR CONNECTOR. 1) Disconnect the connector from the main fan motor. 2) Measure the resistance of the harness between main fan relay 2 connector and main fan motor connector. Connector & terminal (B473) No. 2 — (B497) No. 21: CHECK MAIN FAN MOTOR AND GROUND Is the resistance less than 5 Ω? Go to step 16. CIRCUIT. Measure the resistance between main fan motor connector and chassis ground. Connector & terminal (B473) No. 1 — Chassis ground:

CHECK FOR POOR CONTACT. Check poor contact of main fan motor connector. CHECK MAIN FAN MOTOR. Connect the battery positive (+) terminal to terminal No. 2 of the main fan motor, and the ground (–) terminal to terminal No. 1.

Is there poor contact of the main fan motor connector?

No Go to step 12.

Replace the sub fan motor. Replace the main fan relay 2. Repair the open circuit of the harness between main fan relay 2 connector and main fan motor connector.

Repair the open circuit of the harness between main fan motor connector and chassis ground or poor contact of the joint connector. Go to step 17.

Repair the poor contact of main fan motor connector. Does the radiator main fan Go to step 18. Replace the main rotate? fan motor. CHECK HARNESS BETWEEN SUB FAN RE- Is the resistance less than 1 Ω? Go to step 19. Repair the open LAY CONNECTOR AND ECM. circuit of harness between sub fan 1) Disconnect the connectors from ECM. relay connector 2) Measure the resistance between the sub and ECM. fan relay connector and ECM connector. Connector & terminal (B135) No. 11 — (B497) No. 12: CHECK FOR POOR CONTACT. Is there poor contact of ECM Repair the poor Check the DTC. Check for poor contact of ECM connector. connector? contact of ECM Repair the trouble connector. cause.

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Radiator Fan System COOLING

20

21

22

23

24

25

26

27

28

Step CHECK MAIN FAN RELAY 1. 1) Turn the ignition switch to OFF. 2) Remove the main fan relay 1 from A/C relay holder. 3) Measure the resistance between main fan relay 1 terminals. Terminals No. 14 — No. 15: CHECK MAIN FAN RELAY 1. 1) Connect terminals No. 17 and No. 16 of the main fan relay 1 to the battery. 2) Measure the resistance between terminals of main fan relay 1 switch. Terminals No. 14 — No. 15: CHECK HARNESS BETWEEN MAIN FAN RELAY 1 CONNECTOR AND MAIN FAN MOTOR CONNECTOR. 1) Disconnect the connector from the main fan motor. 2) Measure the resistance of the harness between main fan relay 1 connector and main fan motor connector. Connector & terminal (B473) No. 2 — (B497) No. 15: CHECK HARNESS BETWEEN MAIN FAN RELAY 1 CONNECTOR AND ECM. 1) Disconnect the connectors from ECM. 2) Measure the resistance between main fan relay 1 connector and ECM connector. Connector & terminal (B135) No. 12 — (B497) No. 16: CHECK HARNESS BETWEEN MAIN FAN RELAY 2 CONNECTOR AND ECM. Measure the resistance between main fan relay 2 connector and ECM connector. Connector & terminal (B135) No. 12 — (B497) No. 22: CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 8 and 26. 3) Check the condition of fuse. CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is the resistance 1 MΩ or more?

Yes Go to step 21.

No Replace the main fan relay 1.

Is the resistance less than 1 Ω? Go to step 22.

Replace the main fan relay 1.

Is the resistance less than 1 Ω? Go to step 23.

Repair the open circuit of the harness between main fan relay 1 connector and main fan motor connector.

Is the resistance less than 1 Ω? Go to step 24.

Repair the open circuit of the harness between main fan relay 1 connector and ECM.

Is the resistance less than 1 Ω? Go to step 25.

Is the fuse blown out?

Replace the fuse.

Repair the open circuit of the harness between main fan relay 2 connector and ECM. Go to step 26.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector. Go to step 20.

Repair the power supply circuit to the main fuse box. Go to step 28.

Does the radiator sub fan CHECK OPERATION OF RADIATOR FAN. If the both fans do not rotate at high speed in the rotate? condition of step 2, check whether the radiator sub fan is rotating. CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than 1 Ω? Go to step 29. RELAY 2 CONNECTOR. 1) Remove the main fan relay 2 from A/C relay holder. 2) Measure the resistance between main fan relay 2 connector and chassis ground. Connector & terminal (B497) No. 19 — Chassis ground:

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Repair the open circuit of the harness between main fan relay 2 and chassis ground or poor contact of the joint connector.

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Radiator Fan System COOLING

29

30

31

Step CHECK POWER SUPPLY TO MAIN FAN RELAY 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between main fan relay 2 connector and chassis ground. Connector & terminal (B497) No. 20 (+) — Chassis ground (–): CHECK MAIN FAN RELAY 2. 1) Turn the ignition switch to OFF. 2) Remove the main fan relay 2. 3) Measure the resistance between main fan relay 2 terminals. Terminals No. 18 — No. 19: CHECK MAIN FAN RELAY 2. 1) Connect the battery to terminals No. 20 and No. 22 of the main fan relay 2. 2) Measure the resistance between main fan relay 2 terminals. Terminals No. 18 — No. 19:

Check Is the voltage 10 V or more?

Yes Go to step 30.

No Repair the power supply line.

Is the resistance 1 MΩ or more?

Go to step 31.

Replace the main fan relay 2.

Is the resistance less than 1 Ω? Go to step 23.

Replace the main fan relay 2.

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Engine Coolant COOLING

3. Engine Coolant A: REPLACEMENT 1. DRAINING OF ENGINE COOLANT 1) Lift up the vehicle. 2) Remove the under cover. 3) Remove the drain plug to drain engine coolant into container.

NOTE: The SUBARU Super Coolant is especially made for SUBARU engine, which has an aluminum cylinder block, and contains anti-freeze and anti-rust agents. Always use SUBARU Super Coolant, since other coolant may cause corrosion. 3) Fill engine coolant into the reservoir tank up to “FULL” level.

NOTE: Remove the radiator cap so that engine coolant will drain faster.

FULL FULL

LOW LOW

CO-00269

CO-02632

4) Install the drain plug. 5) Install the under cover.

2. FILLING OF ENGINE COOLANT 1) Pour cooling system conditioner from the filler neck.

Cooling system protecting agent: Refer to “SPECIFICATION” for cooling system protecting agent. 2) Pour engine coolant into the radiator up to the filler neck position. Recommended engine coolant: Refer to “SPECIFICATION” for recommended engine coolant. Engine coolant level: Refer to “SPECIFICATION” for engine coolant level. Engine coolant concentration: Refer to “ADJUSTMENT” for the recommended engine coolant concentration.

4) Close the radiator cap and start the engine. Race 5 to 6 times at 3,000 rpm or less, then stop the engine. (Complete this operation within 40 seconds.) 5) Wait for one minute after the engine stops, and open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position. 6) Perform the procedures 4) and 5) again. 7) Attach the radiator cap and reservoir tank cap properly. 8) Start the engine and operate the heater at maximum hot position and the blower speed setting to “LO”. 9) Run the engine at 2,000 rpm or less until radiator fan starts and stops. NOTE: Be careful with the engine coolant temperature gauge to prevent overheating. 10) Stop the engine and wait until the engine coolant temperature lowers to 30°C (86°F) or less. 11) Open the radiator cap. If the engine coolant level drops, fill engine coolant up to the radiator filler neck position and to the reservoir tank “FULL” level. 12) Attach the radiator cap correctly. 13) Set the heater setting to maximum hot position and the blower speed setting to “LO” and start the engine. Perform racing at 3,000 rpm or less. If the flowing sound is heard from heater core, repeat the procedures from step 9).

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Engine Coolant COOLING

B: ADJUSTMENT 1. PROCEDURE TO ADJUST THE SUBARU SUPER COOLANT CONCENTRATION CAUTION: SUBARU Super Coolant concentration must be used from 50 to 60% to assure the best performance of the anti-freeze and anti-rust agents. To adjust the concentration of SUBARU Super Coolant according to temperature, find the proper SUBARU Super Coolant concentration in the table, and add diluting water to the SUBARU Super Coolant (concentrated type) until it reaches the proper dilution. Relationship of SUBARU Super Coolant concentration and freezing temperature SUBARU Super Coolant concentration 50% 55% Freezing temperature –36°C (–33°F) –41°C (–42°F)

60% –50°C (–58°F)

Recommended Engine Coolant and Water for Dilution: Refer to “SPECIFICATION” for the recommended engine coolant and diluting water.

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Water Pump COOLING

4. Water Pump

12) Remove the water pump.

A: REMOVAL 1) Remove the radiator. 2) Remove the V-belts. 3) Remove the crank pulley. 4) Remove the timing belt cover. 5) Remove the timing belt. 6) Remove the automatic belt tension adjuster.

CO-00021

B: INSTALLATION 1) Install the water pump onto cylinder block LH. NOTE: • Use a new gasket. • When installing the water pump, tighten bolts in two stages in alphabetical order as shown in the figure.

CO-00016

7) Remove the camshaft position sensor. 8) Remove the cam sprocket LH. 9) Remove the belt cover No. 2 LH.

Tightening torque: 1st 12 N·m (1.2 kgf-m, 8.9 ft-lb) Second 12 N·m (1.2 kgf-m, 8.9 ft-lb) (B) (C) (A) (D)

(E)

(F)

ME-04425

2) Install the hose to water pump. 3) Install the tensioner bracket.

Tightening torque: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb) CO-00019

10) Remove the tensioner bracket.

CO-00020

4) Install the belt cover No. 2 LH. CO-00020

11) Disconnect the hose from water pump.

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Water Pump COOLING

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

5) After water pump installation, check pulley shaft for engine coolant leaks or noise. If leaks or noise are noted, replace the water pump assembly.

CO-00019

5) Install the cam sprocket LH. 6) Install the camshaft position sensor. 7) Install an automatic belt tension adjuster with the tension rod held by a pin. 8) Install the timing belt. 9) Install the timing belt cover. 10) Install the crank pulley. 11) Install the V-belts. 12) Install the radiator.

C: INSPECTION 1) Check the water pump bearing for smooth rotation. 2) Check the water pump pulley for abnormalities. 3) Make sure the impeller is not abnormally deformed or damaged. 4) Inspect the clearance between impeller and pump case.

Clearance between impeller and pump case: Standard 0.5 — 1.5 mm (0.020 — 0.060 in)

CO-00293

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Thermostat COOLING

5. Thermostat

B: INSTALLATION

A: REMOVAL

1) Install a gasket to thermostat.

1) Lift up the vehicle. 2) Remove the under cover. 3) Drain engine coolant. 4) Disconnect the radiator outlet hose from thermostat cover.

NOTE: Install the parts with the jiggle pin facing upside.

NOTE: Use a new gasket. 2) Install the thermostat and thermostat cover.

Tightening torque: 12 N·m (1.2 kgf-m, 8.9 ft-lb)

CO-00270 (D)

5) Remove the thermostat cover, and then remove the gasket and thermostat. T

(C) (B) (A) CO-02669

(A) (B) (C) (D)

(C) (B)

(A) CO-02649

Thermostat cover Gasket Thermostat Jiggle pin

3) Connect the radiator outlet hose to thermostat cover. 4) Install the under cover. 5) Lower the vehicle. 6) Fill engine coolant.

(A) Thermostat cover (B) Gasket (C) Thermostat

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Thermostat COOLING

C: INSPECTION 1) Check that the thermostat does not have deformation, cracks or damage. 2) Check that the thermostat valve closes completely at an ambient temperature. 3) Immerse the thermostat and a thermometer in water. Raise water temperature gradually, and check the temperature and valve lift when the valve begins to open and when the valve is fully opened. Replace the thermostat if faulty. NOTE: • During the test, agitate the water for even temperature distribution. • Leave the thermostat in the boiling water for five minutes or more before measuring the valve lift. • Hold the thermostat with a wire or the like to avoid contacting the container bottom.

Starting temperature to open: 86 — 90°C (187 — 194°F) Full open temperature: 95°C (203°F) Total valve lift: 9.0 mm (0.354 in) or more

(A)

(B)

CO-02420

(A) Thermometer (B) Thermostat

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Radiator COOLING

6. Radiator A: REMOVAL CAUTION: The radiator is pressurized when the engine and radiator are hot. Wait until engine and radiator cools down before working on the radiator. 1) Disconnect the ground cable from battery.

9) Remove the reservoir tank. 10) Disconnect the connectors of main fan motor (A) and sub fan motor (B).

(A)

(B)

IG-02107

2) Lift up the vehicle. 3) Remove the under cover. 4) Drain engine coolant. 5) Disconnect the radiator outlet hose from thermostat cover.

CO-02625

11) Disconnect the radiator inlet hoses from the engine.

CO-00270

6) Disconnect the CVTF cooler hoses from CVTF pipes. (CVT model) NOTE: Plug the CVTF pipe to prevent CVTF from leaking.

CO-02624

CO-02617

12) Remove the grille bracket. NOTE: Remove ten clips when removing the grille bracket.

CO-02618 CO-02664

7) Lower the vehicle. 8) Remove the air intake duct.

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Radiator COOLING

Tightening torque: 12 N·m (1.2 kgf-m, 8.9 ft-lb)

13) Remove the radiator upper brackets.

CO-02619

14) Lift the radiator up and away from vehicle. 15) Remove the radiator lower cushion from the vehicle body.

CO-02619

4) Attach the grille bracket.

CO-02618 CO-02620

5) Connect the radiator inlet hose.

B: INSTALLATION 1) Install the radiator lower cushion to the vehicle body.

CO-02617

CO-02620

2) Install the radiator to the vehicle. NOTE: Insert the pin on the lower side of radiator into the radiator lower cushion. 3) Install the radiator upper brackets.

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Radiator COOLING

6) Connect the connectors of radiator main fan motor connector (A) and sub fan motor connector (B).

(A)

12) Install the under cover. 13) Lower the vehicle. 14) Connect the ground cable to battery.

CO-02624 IG-02107

15) Fill engine coolant. 16) Adjust the CVTF level. (CVT model)

(B)

C: INSPECTION CO-02625

7) Install the air intake duct. 8) Install the reservoir tank. 9) Lift up the vehicle. 10) Connect the CVTF cooler hoses. (CVT model)

1) Check that the radiator does not have deformation, cracks or damage. 2) Check that the hose has no cracks, damage or loose part. 3) Remove the radiator cap, fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.

NOTE: Use a new CVTF hose.

CO-02588

CO-02664

11) Connect the radiator outlet hose.

4) Apply a pressure of 157 kPa (1.6 kgf/cm2, 23 psi) to the radiator, and check the following items. • Leakage from the radiator or its vicinity • Leakage from the hose or its connections CAUTION: • Engine should be turned off. • Wipe engine coolant from check points in advance. • Be careful of engine coolant from spurting out when removing the radiator cap tester. • Be careful not to deform the filler neck of radiator when installing and removing the radiator cap tester.

CO-00270

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Radiator Cap COOLING

7. Radiator Cap A: INSPECTION 1) Check that the radiator cap does not have deformation, cracks or damage. 2) Attach the radiator cap tester to radiator cap.

CO-00044

3) Increase pressure until the radiator cap tester gauge needle stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 — 6 seconds. Replace the radiator cap if its valve opens at less than the service limit.

Standard: 93 — 123 kPa (0.95 — 1.25 kgf/cm2, 14 — 18 psi) Service limit: 83 kPa (0.85 kgf/cm2, 12 psi) CAUTION: Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect.

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Radiator Main Fan and Fan Motor COOLING

8. Radiator Main Fan and Fan Motor

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

A: REMOVAL 1) Disconnect the ground cable from battery.

CO-02621

C: DISASSEMBLY IG-02107

2) Remove the reservoir tank. 3) Disconnect the connector (A) of the main fan motor assembly.

(A)

1) Remove the clip which holds the main fan motor assembly connector onto the radiator main fan shroud. 2) Remove the bolts which hold the main fan motor assembly onto the radiator main shroud.

CO-00098 CO-02624

4) Remove the CVTF hose from the clip of the radiator main fan shroud. (CVT model) 5) Remove the bolts which hold the radiator main fan shroud to the radiator.

D: ASSEMBLY Assemble in the reverse order of disassembly.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

CO-02621

6) Remove the radiator main fan and fan motor from vehicle.

B: INSTALLATION CAUTION: Confirm that the radiator hose is securely connected. Install in the reverse order of removal.

CO-00098

E: INSPECTION Check that the radiator main fan, radiator main fan shroud and main fan motor assembly do not have deformation, cracks or damage.

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Radiator Sub Fan and Fan Motor COOLING

9. Radiator Sub Fan and Fan Motor

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

A: REMOVAL 1) Disconnect the ground cable from battery.

CO-02622

C: DISASSEMBLY IG-02107

2) Remove the air intake duct. 3) Remove the connector (B) of sub fan motor assembly.

1) Remove the clip which holds the radiator sub fan motor assembly connector onto the radiator sub fan shroud. 2) Remove the bolts which hold the sub fan motor assembly onto the radiator sub fan shroud.

(B)

CO-00098 CO-02625

4) Remove the CVTF hose from the clip of the radiator sub fan & fan motor assembly. (CVT model) 5) Remove the bolts which hold the radiator sub fan shroud to the radiator.

D: ASSEMBLY Assemble in the reverse order of disassembly.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

CO-02622

6) Remove the radiator sub fan and fan motor from vehicle.

B: INSTALLATION CAUTION: Confirm that the radiator hose is securely connected. Install in the reverse order of removal.

CO-00098

E: INSPECTION Check that the radiator sub fan, radiator sub fan shroud and sub fan motor assembly do not have deformation, cracks or damage.

CO(H4SO)-25

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Reservoir Tank COOLING

10.Reservoir Tank A: REMOVAL 1) Pull out the over flow hose (A) from the reservoir tank. 2) Pull out the reservoir tank to the arrow direction while pushing the claw (B). (B)

(A) CO-02623

B: INSTALLATION Install in the reverse order of removal.

C: INSPECTION 1) Check that the reservoir tank does not have deformation, cracks or damage. 2) Make sure the over flow hoses are not cracked, damaged or loose. 3) Make sure the engine coolant level is between “FULL” and “LOW”.

CO(H4SO)-26

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Engine Cooling System Trouble in General COOLING

11.Engine Cooling System Trouble in General A: INSPECTION Trouble

Possible cause

Corrective action Replenish engine coolant, inspect for leakage, and repair it if necessary. Repair or replace timing belt tensioner. Replace. Replace. Replace. Clean. Inspect and repair ignition control system.

Clean, repair or replace. Replace.

a. Insufficient engine coolant b. Loose timing belt c. Oil on timing belt d. Malfunction of thermostat e. Malfunction of water pump f. Clogged engine coolant passage g. Improper ignition timing Over-heating

h. Clogged or leaking radiator i. Defective radiator fan j. Improper engine oil in engine coolant

Replace the engine coolant. If ineffective, check, repair or replace engine components.

Inspect and repair the fuel injection system. l. Excessive back pressure in exhaust system Clean or replace. m. Insufficient clearance between piston and cylinder Adjust or replace. n. Slipping clutch Repair or replace. o. Dragging brake Adjust.

k. Air/fuel mixture ratio too lean

p. Defective radiator fan Over-cooling

Engine coolant leaks

Noise

a. Ambient temperature extremely low b. Defective thermostat a. Loosened or damaged connecting units on hoses b. Leakage from water pump c. Leakage from water pipe d. Leakage around cylinder head gasket e. Damaged or cracked cylinder head and cylinder block f. Damaged or cracked thermostat cover g. Leakage from radiator a. Timing belt problem b. Defective radiator fan c. Defective water pump bearing d. Defective water pump mechanical seal

Inspect the radiator fan relay, engine coolant temperature sensor or fan motor and replace them. Partly cover radiator front area. Replace. Repair or replace. Replace. Repair or replace. Retighten cylinder head bolts or replace cylinder head gasket. Repair or replace. Repair or replace. Repair or replace. Replace. Replace. Replace water pump. Replace water pump.

CO(H4SO)-27

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Engine Cooling System Trouble in General COOLING

CO(H4SO)-28

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2015年12月24日 木曜日 午後5時18分

LUBRICATION

LU(H4SO) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Page General Description ...................................................................................2 Oil Pressure System ................................................................................10 Engine Oil .................................................................................................12 Oil Pump ..................................................................................................14 Oil Pan and Strainer .................................................................................18 Oil Pressure Switch ..................................................................................23 Engine Oil Cooler .....................................................................................25 Oil Catch Tank .........................................................................................27 Scavenge Pump .......................................................................................28 Oil Pipe .....................................................................................................29 Engine Oil Filter ........................................................................................34 Oil Level Switch ........................................................................................35 Engine Lubrication System Trouble in General ........................................42

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General Description LUBRICATION

1. General Description A: SPECIFICATION • 2.5 L non-turbo model Lubrication method Pump type

Forced lubrication Trochoid type

Inner rotor Outer rotor Outer rotor diameter × thickness Tip clearance between inner and outer rotors Number of teeth

Oil pump

mm (in) mm (in) Standard

Case clearance between outer rotor and mm (in) Standard pump case Side clearance between inner rotor and mm (in) Standard pump case Free length Relief valve spring Installed length Load when installed 600 rpm Performance (Oil temperature 80°C (176°F)) 5,000 rpm

0.04 — 0.14 (0.0016 — 0.0055) 0.10 — 0.175 (0.0039 — 0.0069) 0.02 — 0.07 (0.0008 — 0.0028) mm (in) mm (in) N (kgf, lbf)

Discharge pressure

kPa (kgf/cm2, psi)

Discharge rate

2 (US qt, Imp qt)/min.

Discharge pressure Discharge rate

kPa (kgf/cm2, psi) 2 (US qt, Imp qt)/min.

Relief valve working pressure

kPa

(kgf/cm2,

psi)

Filter type

Oil filter

Outer diameter: 68 mm (2.68 in) (black) Filtration area cm2 (sq in) Outer diameter: 67.4 mm (2.65 in) (blue) By-pass valve opening pressure kPa (kgf/cm2, psi) Outer diameter: 68 mm (2.68 in) (black) Outer diameter × width mm (in) Outer diameter: 67.4 mm (2.65 in) (blue) Installation screw specifications

Oil pressure switch

Engine oil

9 10 76 × 10 (2.99 × 0.39)

73.7 (2.902) 54.7 (2.154) 93.1 (9.49, 20.93) 98 (1.0, 14) 4.6 (4.9, 4.0) or more 294 (3.0, 43) 47.0 (49.7, 41.4) or more 588 (6.0, 85) Full-flow filter type 800 (124) 555 (86) 160 (1.63, 23.2) 68 × 65 (2.68 × 2.56) 67.4 × 65.3 (2.65 × 2.57) M 20 × 1.5

Type Operating voltage — power consumption Warning light operating pressure Proof pressure Total capacity (at overhaul) When replacing engine oil and oil filter When replacing engine oil only

LU(H4SO)-2

kPa (kgf/cm2, psi) kPa (kgf/cm2, psi) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt)

Immersed contact point type 12 V — 3.4 W or less 14.7 (0.15, 2.1) 981 (10, 142) or more 4.8 (5.1, 4.2) 4.2 (4.4, 3.7) 4.0 (4.2, 3.5)

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General Description LUBRICATION

• Turbo model Lubrication method Pump type

Forced lubrication Trochoid type

Inner rotor Outer rotor Outer rotor diameter × thickness Tip clearance between inner and outer rotors Case clearance between outer rotor and pump case Side clearance between inner rotor and pump case Number of teeth

Oil pump

Relief valve spring

mm (in) mm (in) Standard

0.04 — 0.14 (0.0016 — 0.0055)

mm (in) Standard

0.10 — 0.175 (0.0039 — 0.0069)

mm (in) Standard

0.02 — 0.07 (0.0008 — 0.0028)

Free length Installed length Load when installed Discharge pressure Discharge rate

600 rpm Performance (Oil temperature 80°C (176°F)) 6,000 rpm

Discharge pressure Discharge rate

mm (in) mm (in) N (kgf, lbf) kPa (kg/cm2, psi) 2 (US qt, Imp qt)/min. kPa (kg/cm2, psi) 2 (US qt, Imp qt)/min.

Relief valve working pressure Filter type

Oil filter

kPa (kg/cm

2,

psi)

Engine oil

73.7 (2.902) 54.7 (2.154) 93.1 (9.49, 20.93) 98 (1.0, 14) 6.4 (6.8, 5.6) or more 392 (4.0, 56.8) 63.0 (66.6, 55.4) or more 538 (5.5, 78) Full-flow filter type

Outer diameter: 68 mm (2.68 in) (black) Filtration area cm2 (sq in) Outer diameter: 67.4 mm (2.65 in) (blue) By-pass valve opening pressure kPa (kg/cm2, psi) Outer diameter: 68 mm (2.68 in) (black) Outer diameter × width mm (in) Outer diameter: 67.4 mm (2.65 in) (blue) Installation screw specifications

Oil pressure switch

9 10 78 × 11 (3.07 × 0.43)

800 (124) 555 (86) 160 (1.63, 23.2) 68 × 65 (2.68 × 2.56) 67.4 × 65.3 (2.65 × 2.57) M 20 × 1.5

Type Operating voltage — power consumption Warning light operating pressure Proof pressure Total capacity (at overhaul) When replacing engine oil and oil filter When replacing engine oil only

LU(H4SO)-3

kPa (kg/cm2, psi) kPa (kg/cm2, psi) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt)

Immersed contact point type 12 V — 3.4 W or less 14.7 (0.15, 2.1) 981 (10, 142) or more 5.2 (5.5, 4.6) 4.3 (4.5, 3.8) 4.0 (4.2, 3.5)

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2015年12月24日 木曜日 午後5時18分

General Description LUBRICATION

Recommended oil: Oil corresponding to either of the following standards. • Those with SM “Energy Conserving” logo in case of API standard. • Those with GF-4 “starburst mark” displayed on top of the container in case of ILSAC standard. SAE (1) ( C) -30 -20 -15 ( F) -22 -4 5

0

15

30

32

59

86 104

40

10W-30, 10W-40 , 10W-50 5W-30 (2), 5W-40

LU-02488

(1) SAE viscosity No. and applicable temperature (2) Recommended

CAUTION: It is acceptable to fill an engine with oil of another brand when replacing the oil, but make sure to use an oil with an API standard and SAE viscosity number specified by Subaru. NOTE: • The proper viscosity oil helps the engine maintain its ideal temperature, and cranking speed increased by reducing viscosity friction in hot condition. • If the vehicle is used in regions of high temperatures or in other severe environments, use oil with the viscosities shown below. API standard: SM or SL SAE viscosity No.: 30, 40, 10W-50, 20W-40, 20W50

LU(H4SO)-4

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2015年12月24日 木曜日 午後5時18分

General Description LUBRICATION

B: COMPONENT • 2.5 L non-turbo model (13)

T6

(16) (15) (14) T3 (17)

(12) (29) (28)

(11) T3

(18) (32) T10

T3 T3

T4

T3 (9)

T2

(20)

(8) (6)

T9

T3

(19)

(31)

(33)

(7)

(36) (27)

(24) (30)

(35)

T3

(10)

(5) (4)

(2) T5

T3

(34)

(3)

(1)

T8

(23)

(21)

(22)

T1 T7

LU(H4SO)-5

(26) (25)

LU-02595

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General Description LUBRICATION (1) (2)

PLUG Gasket

(17) (18)

O-ring Baffle plate

(33) (34)

O-ring Oil drain pipe

(3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Relief valve spring Relief valve Front oil seal Oil pump case Inner rotor Outer rotor Oil pump cover Oil filter O-ring Oil pump ASSY Oil pressure switch Oil filler duct Gasket Oil filler cap

(19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32)

O-ring Oil strainer Oil level gauge guide O-ring Oil pan Oil level gauge Drain plug Drain plug gasket Cylinder block lower Seal Rocker cover O-ring Oil filter connector PLUG

(35) (36)

O-ring Oil level switch

LU(H4SO)-6

Tightening torque:N·m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 5.4 (0.6, 4.0) T3: 6.4 (0.7, 4.7) T4: 10 (1.0, 7.4) T5: 16 (1.6, 11.8) T6: 25 (2.5, 18.4) T7: 41.7 (4.3, 30.8) T8: 44 (4.5, 32.5) T9: 45 (4.6, 33.2) T10: 70 (7.1, 51.6)

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General Description LUBRICATION

• Turbo model (30)

(16)

T6

(33)

T3

(17)

(18) (44) (19)

T3 (31) (15)

(20)

T10 (14)

(35) (37)

(29) (36)

T3 (13) T3

(9)

(37)

T2

T4

T3 (37) (22)

(37)

(8)

(36)

T3

(21) (42)

(6)

(7)

(11) T9

(38) (12)

(23)

(41) (40)

T3

(34) (26)

T3

(39)

(5) (4)

T3

T5

T3

(43)

(2)

(24)

(25) (3)

(1)

T8

(32) T1 (10) T7

LU(H4SO)-7

(27) (28)

LU-02596

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General Description LUBRICATION (1) (2)

PLUG Gasket

(21) (22)

O-ring Oil strainer

(41) (42)

Oil level switch O-ring

(3)

Relief valve spring

(23)

Cylinder block lower

(43)

Oil drain pipe

(4)

Relief valve

(24)

Oil level gauge guide

(44)

Scavenge pump

(5)

Front oil seal

(25)

Oil pan

(6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

Oil pump case Inner rotor Outer rotor Oil pump cover Oil filter Oil cooler connector Oil cooler pipe Oil cooler O-ring Oil pump ASSY Oil pressure switch Oil filler duct

(26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37)

Oil level gauge Drain plug gasket Drain plug Gasket Oil filler cap Seal O-ring Gasket O-ring PLUG Oil cooler hose Clip

(18)

O-ring

(38)

Oil cooler pipe stay

(19)

Rocker cover

(39)

O-ring

(20)

Baffle plate

(40)

O-ring

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. • If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. • Prepare a container and cloth when performing work which oil possibly spills. If oil spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing of oil.

LU(H4SO)-8

Tightening torque:N·m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 5.4 (0.6, 4.0) T3: 6.4 (0.7, 4.7) T4: 10 (1.0, 7.0) T5: 16 (1.6, 11.8) T6: 25 (2.5, 18.4) T7: 41.7 (4.3, 30.8) T8: 44 (4.5, 32.5) T9: 54 (5.5, 39.8) T10: 69 (7.0, 50.9)

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General Description LUBRICATION

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 18332AA000

DESCRIPTION OIL FILTER WRENCH

REMARKS Used for removing and installing black oil filter (outer diameter: 68 mm (2.68 in)).

ST18332AA000

499587100

OIL SEAL INSTALLER

Used for installing oil pump oil seal.

ST-499587100

2. GENERAL TOOL TOOL NAME Oil filter wrench (65/67 mm 14 flutes) Circuit tester

REMARKS Used for removing and installing blue oil filter (outer diameter: 67.4 mm (2.65 in)). Used for measuring resistance and voltage.

LU(H4SO)-9

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2015年12月24日 木曜日 午後5時18分

Oil Pressure System LUBRICATION

2. Oil Pressure System A: WIRING DIAGRAM TO POWER SUPPLY CIRCUIT

OIL PRESSURE WARNING LIGHT

19

FB-30 F/B FUSE NO. 5 (IG)

COMBINATION METER

8

i 10

35

i1 B 36

*

B 21 E2

E 11

*

: 2.5 L NON-TURBO MODEL : 31 2.5 L TURBO MODEL

: 45

OIL PRESSURE SWITCH i10

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

B36

(BLACK)

39 52

40 46 53

41 47

1

2

10 11

12

13

14 15 16 17 18 19 20 21 22 23 24 25 26

27

28

29 30 31 32 33 34 35 36 37 38 39 40 41 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

42

3

4

5

6

7

8

9

54

LU-02597

LU(H4SO)-10

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Oil Pressure System LUBRICATION

B: INSPECTION 1

2

3

Step Check CHECK COMBINATION METER. Does the warning light illumi1) Turn the ignition switch to ON. (engine OFF) nate? 2) Check the warning light in the combination meter.

Yes Go to step 2.

CHECK HARNESS CONNECTOR BETWEEN Is the voltage 10 V or more? COMBINATION METER AND OIL PRESSURE SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from oil pressure switch. 3) Turn the ignition switch to ON. 4) Measure the voltage of harness between oil pressure switch connector and chassis ground. Connector & terminal (E11) No. 1 (+) — Chassis ground (–): CHECK COMBINATION METER. Is the resistance less than 10 1) Turn the ignition switch to OFF. Ω? 2) Remove the combination meter. 3) Measure the resistance of combination meter. Terminals (i10) No. 8 — No. 19:

Replace the oil pressure switch.

LU(H4SO)-11

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between combination meter and oil pressure switch • Poor contact of combination meter connector • Poor contact of oil pressure switch connector • Poor contact of coupling connector

No Repair or replace the combination meter. Go to step 3.

Repair or replace the combination meter.

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Engine Oil LUBRICATION

3. Engine Oil

B: REPLACEMENT

A: INSPECTION

CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Open the oil filler cap for quick draining of engine oil. 2) Lift up the vehicle. 3) Remove the service hole cover of under cover. (Large under cover model)

CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe away the oil. 3) Reinsert the oil level gauge all the way. Be sure that the oil level gauge is correctly inserted and properly orientated. 4) Pull out the oil level gauge again, and check the oil level. If the engine oil level is below “L” line, check for oil leakage from engine and add oil to bring the level up to “F” line. 5) Start the engine to circulate the oil in engine room. 6) After turning off the engine, wait a few minutes for the oil to return to the oil pan before checking the level. NOTE: • Just after driving or while the engine is warm, engine oil level shows in the range between the “F” line and the notch mark. This is caused by thermal expansion of engine oil. • To prevent overfilling of engine oil, do not add oil above “F” line when the engine is cold. • As the oil level gauge is used for daily inspection, “F” line and “L” line are set assuming that the engine is cold. (A)

(B)

LU-02570

4) Drain engine oil by loosening the drain plug. NOTE: Prepare the container for draining of engine oil. • Models with small and medium under cover

(F) LU-02571 (C)

• Models with large under cover

(E) (D)

LU-02569

(A) (B) (C) (D) (E) (F)

Oil level gauge Oil filler cap “F” line “L” line Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt) Notch mark

LU-02572

5) Tighten the drain plug after draining engine oil. NOTE: Use a new drain plug gasket.

Tightening torque: 41.7 N·m (4.3 kgf-m, 30.8 ft-lb)

LU(H4SO)-12

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Engine Oil LUBRICATION

• Models with small and medium under cover

11) After stopping the engine, recheck the oil level. If necessary, add engine oil up to the “F” line on oil level gauge. (A)

(B)

(F)

(C) (E) (D) LU-02571

• Models with large under cover

LU-02569

(A) (B) (C) (D) (E) (F)

LU-02572

6) Install the service hole cover of under cover. (Large under cover model)

LU-02570

7) Lower the vehicle. 8) Using engine oil of proper quality and viscosity, fill engine oil through the oil filler duct to the “F” line on oil level gauge. Make sure that the vehicle is parked on a level surface when checking oil level.

Recommended oil: Refer to “SPECIFICATION” for recommended oil. Engine oil capacity: Refer to “SPECIFICATION” for engine oil capacity. 9) Close the oil filler cap. 10) Start the engine to circulate the oil in engine room.

LU(H4SO)-13

Oil level gauge Oil filler cap “F” line “L” line Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt) Notch mark

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Oil Pump LUBRICATION

4. Oil Pump A: REMOVAL 1) Remove the collector cover. (turbo model) 2) Disconnect the ground cable from battery.

NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.

LU-00015 IG-02107

3) Remove the radiator. 4) Remove the crankshaft position sensor. 5) Remove the water pump. 6) Remove the crank sprocket.

8) Remove the oil pump by using flat tip screwdriver. CAUTION: Be careful not to damage the mating surface of the cylinder block and oil pump.

LU-00016

9) Remove the front oil seal from the oil pump.

B: INSTALLATION 1) Using the ST, install the front oil seal. ST 499587100 OIL SEAL INSTALLER NOTE: Use a new front oil seal. LU-02111

7) Remove the bolts which install oil pump onto cylinder block. ST

LU-00021

2) Apply liquid gasket to the mating surfaces of oil pump. NOTE: Install within 5 min. after applying liquid gasket.

LU(H4SO)-14

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Oil Pump LUBRICATION

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(A) T ME-00165

(A) O-ring

3) Apply a coat of engine oil to the inside of front oil seal.

ME-04112

6) Install the crank sprocket. 7) Install the water pump. 8) Install the crankshaft position sensor. 9) Install the radiator. 10) Connect the ground cable to battery.

ME-00312

4) Install the oil pump to cylinder block. CAUTION: • Be careful not to damage the front oil seal during installation. • Make sure the front oil seal lip is not folded. NOTE: • Align the flat surface of oil pump’s inner rotor with flat surface of crankshaft before installation. • Use new O-rings. • Do not forget to assemble O-rings. 5) Apply liquid gasket to the three bolts thread shown in figure. (when reusing bolts)

Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent

IG-02107

C: DISASSEMBLY Remove the screw which secures oil pump cover and then disassemble oil pump. Inscribe alignment marks on the inner and outer rotors so that they can be replaced in their original positions during reassembly.

LU(H4SO)-15

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Oil Pump LUBRICATION

NOTE: Before disassembling the oil pump, remove the relief valve. (E)

4) Install the oil relief valve and relief valve spring and plug. NOTE: Use a new gasket. 5) Install the oil pump cover.

Tightening torque: T1: 5.4 N·m (0.6 kgf-m, 4.0 ft-lb) T2: 44 N·m (4.5 kgf-m, 32.5 ft-lb)

(D) (C)

(B)

T1 (E) (A)

(D) (I)

(F)

(B)

(C)

(A)

(G) (H)

(F)

(G)

(I)

(H)

LU-00020

(A) (B) (C) (D) (E) (F) (G) (H) (I)

Front oil seal Oil pump case Inner rotor Outer rotor Oil pump cover Relief valve Relief valve spring Plug Gasket

T2

LU-02134

(A) (B) (C) (D) (E) (F) (G) (H) (I)

D: ASSEMBLY 1) Using the ST, install the front oil seal. ST 499587100 OIL SEAL INSTALLER NOTE: Use a new front oil seal.

ST

LU-00021

2) Apply a coat of engine oil to inner and outer rotors. 3) Install the inner and outer rotors.

LU(H4SO)-16

Front oil seal Oil pump case Inner rotor Outer rotor Oil pump cover Relief valve Relief valve spring PLUG Gasket

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Oil Pump LUBRICATION

E: INSPECTION

3. SIDE CLEARANCE

1. TIP CLEARANCE

Measure the gap between the inner rotor and the oil pump case to measure the clearance between the inner rotor and the oil pump cover as shown in the figure. If clearance is out of standard, replace the rotor or the oil pump case.

Measure the tip clearance of rotors. If the clearance is out of standard, replace the rotors as a set.

Tip clearance between inner and outer rotors: Standard 0.04 — 0.14 mm (0.0016 — 0.0055 in)

Side clearance between inner rotor and pump case: Standard 0.02 — 0.07 mm (0.0008 — 0.0028 in)

LU-00023

2. CASE CLEARANCE Measure the clearance between outer rotor and oil pump case. If clearance is out of standard, replace the oil pump case.

Case clearance between outer rotor and pump case: Standard 0.10 — 0.175 mm (0.0039 — 0.0069 in)

LU-00025

4. OIL RELIEF VALVE Check the valve for assembly condition and damage, and the relief valve spring for damage and deterioration. Replace the parts if defective.

Relief valve spring: Free length 73.7 mm (2.902 in) Installed length 54.7 mm (2.154 in) Load when installed 93.1 N (9.49 kgf, 20.93 lbf)

5. OIL PUMP CASE Check for worn shaft hole, clogged oil passage, worn rotor chamber, cracks and other faults. LU-00024

6. FRONT OIL SEAL Check the front oil seal lips for deformation and hardening, wear.

LU(H4SO)-17

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Oil Pan and Strainer LUBRICATION

5. Oil Pan and Strainer

2) Disconnect the ground cable from battery.

A: REMOVAL 1. OIL PAN 1) Disconnect the ground cable from battery.

IG-02107

IG-02107

2) Lift up the vehicle. 3) Remove the under cover. 4) Drain the engine oil. 5) Remove the front exhaust pipe.

6) Remove the bolts which secure the oil pan to the cylinder block lower.

3) Remove the air intake boot assembly. (2.5 L non-turbo model) 4) Remove the intercooler. (turbo model) 5) Support the engine with a lifting device and wire ropes.

LU-00222

6) Lift up the vehicle.

LU-02583

7) Insert an oil pan cutter blade into the gap between cylinder block lower and oil pan, and remove the oil pan. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.

CAUTION: When lifting up the vehicle, raise up wire ropes at the same time. 7) Remove the oil pan. 8) Remove the engine mounting.

9) Remove the bolts which secure the cylinder block lower to the cylinder block.

2. CYLINDER BLOCK LOWER 1) Remove the collector cover. (turbo model)

LU-02584

10) Insert a flat tip screwdriver into the gap between cylinder block and cylinder block lower, and remove the cylinder block lower.

LU(H4SO)-18

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Oil Pan and Strainer LUBRICATION

CAUTION: Insert the flat tip screwdriver to the position shown in the figure, and be careful not to damage the mating surface of the cylinder block and cylinder block lower.

B: INSTALLATION 1. OIL PAN NOTE: Before installing the oil pan, clean the mating surface of oil pan and cylinder block. 1) Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan. NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent ME-04426

11) Remove the oil strainer from cylinder block lower. 12) Remove the oil level switch from cylinder block lower. 13) Remove the baffle plate. (G)

LU-02580

2) Tighten the bolts which install oil pan to cylinder block lower.

(I)

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

(F)

(E) (H) (D) (K) (C)

(J)

(B) (A)

LU-02583 LU-02598

(A) Oil pan (B) Oil drain pipe (C) Cylinder block lower (D) (E) (F) (G) (H) (I) (J) (K)

O-ring Oil strainer Baffle plate Cylinder block O-ring Seal O-ring Oil level switch

3) Install the front exhaust pipe. 4) Install the under cover. 5) Lower the vehicle.

LU(H4SO)-19

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Oil Pan and Strainer LUBRICATION

6) Connect the ground cable to battery.

(2) Using a tool such as plastic hammer, insert oil drain pipe to the reference line (A). NOTE: Be careful not to deform the oil drain pipe.

(A) IG-02107

7) Refill the engine oil. LU-02601

2. CYLINDER BLOCK LOWER NOTE: Before installing the cylinder block lower, clean the mating surface of cylinder block lower and cylinder block. 1) Make sure that the seals (A) are installed securely on the baffle plate in a direction as shown in the figure below.

(3) Measure protrusion amount “L” of oil drain pipe shown in the figure to ensure that it is within the standard.

Protrusion amount L of oil drain pipe: Standard 89.0 — 91.0 mm (3.50 — 3.58 in)

NOTE: Use a new seal.

L

(A)

LU-02600

4) Install the oil strainer to cylinder block lower. LU-00052

2) Install the baffle plate.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 3) Install the oil drain pipe to cylinder block lower. (1) Use a marker to draw reference line (A) on oil drain pipe as shown in the figure. Protrusion amount L of oil drain pipe: 90.0 mm (3.54 in)

NOTE: Use new O-rings.

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb) 5) Install the O-ring to the cylinder block lower. NOTE: • Use new O-rings. • Install the O-ring with the steel area facing up. 6) Apply liquid gasket to the mating surfaces of oil pan, and install the cylinder block lower. CAUTION: Be careful not to apply any liquid gasket to the O-ring (A). NOTE: Install within 5 min. after applying liquid gasket.

L

(A)

LU-02608

LU(H4SO)-20

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Oil Pan and Strainer LUBRICATION

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

(G)

(A) (I) (F)

T2

T3 (E)

LU-02581

T2

(H) (D)

(A) O-ring

(K) (C)

7) Tighten the bolts which install cylinder block lower to cylinder block.

(J)

T4 (B)

Tightening torque: T1: 5 N·m (0.5 kgf-m, 3.7 ft-lb) T2: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T3: 10 N·m (1.0 kgf-m, 7.4 ft-lb) T4: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T2

(A) T1 LU-02599

(A) (B) (C) (D)

Oil pan Oil drain pipe Cylinder block lower O-ring

(E) (F) (G) (H) (I) (J) (K)

Oil strainer Baffle plate Cylinder block O-ring Seal O-ring Oil level switch

8) Install the engine mounting. 9) Install the oil pan. 10) Lower the vehicle. CAUTION: When lowering the vehicle, lower the lift up device and wire ropes at the same time.

LU(H4SO)-21

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Oil Pan and Strainer LUBRICATION

11) Remove the lifting device and wire ropes.

LU-00222

12) Install the intercooler. (turbo model) 13) Install the air intake boot assembly. (2.5 L nonturbo model) 14) Connect the ground cable to battery.

IG-02107

15) Install the collector cover. (turbo model) 16) Refill the engine oil.

C: INSPECTION Check that the oil pan, oil strainer and baffle plate do not have deformation, cracks or damage.

LU(H4SO)-22

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Oil Pressure Switch LUBRICATION

6. Oil Pressure Switch

B: INSTALLATION

A: REMOVAL

1) Apply liquid gasket to the oil pressure switch threads.

1) Disconnect the ground cable from battery.

Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent

IG-02107

2) Remove the generator. 3) Disconnect the terminal from oil pressure switch.

LU-00129

2) Install the oil pressure switch to cylinder block.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

LU-02615

4) Remove the oil pressure switch. LU-02616

3) Connect the terminal to the oil pressure switch.

LU-02616

LU-02615

4) Install the generator.

LU(H4SO)-23

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Oil Pressure Switch LUBRICATION

5) Connect the ground cable to battery.

IG-02107

C: INSPECTION 1) Check that the oil pressure switch does not have deformation, cracks or damage. 2) Check the oil pressure switch installation portion for oil leakage and oil seepage.

LU(H4SO)-24

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Engine Oil Cooler LUBRICATION

7. Engine Oil Cooler

8) Remove the oil cooler connector (D) and oil cooler (E).

A: REMOVAL CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. NOTE: Turbo model is equipped with engine oil cooler. 1) Lift up the vehicle. 2) Remove the under cover. 3) Drain engine coolant. 4) Remove the front exhaust pipe. 5) Remove the engine oil filter. 6) Remove the bolt (B) holding the oil cooler pipe (A) to the oil pump. 7) Remove the oil cooler pipe (A) and oil cooler hose (C).

(G) (F) (C) (E) (G)

(C) (G) (G)

(D)

(H) (B)

(A) (B)

(A) (B) (C) (D) (E) (F) (G) (H) (I)

LU(H4SO)-25

(B)

Oil cooler pipe BOLT Oil cooler hose Oil cooler connector Oil cooler Gasket Clip Oil cooler pipe stay O-ring

(I)

LU-02573

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Engine Oil Cooler LUBRICATION

B: INSTALLATION

C: INSPECTION

Install in the reverse order of removal.

1) Check that the engine oil cooler, oil cooler pipe and oil cooler connector do not have deformation, cracks or damage. 2) Make sure the oil cooler hoses are not cracked, damaged or loose. 3) Check the coolant paths for clogs while spraying compressed air. 4) Make sure the mating surfaces of the cylinder block do not have damage.

NOTE: • Use new gaskets and O-rings. • Use a new oil cooler hose. • After temporarily tightening the bolts on oil cooler pipe, tighten the bolts in alphabetical order shown in the following figure.

(B) (C) (A) LU-02613

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 54 N·m (5.5 kgf-m, 39.8 ft-lb)

(G) (F) (C) (E) (G)

(G) (B)

(C)

(G) (H)

T1 (D)

T2

(B) T1

(A) (B) (C) (D) (E) (F) (G) (H) (I)

(B)

(A)

T1 (I)

LU-02574

Oil cooler pipe BOLT Oil cooler hose Oil cooler connector Oil cooler Gasket Clip Oil cooler pipe stay O-ring

LU(H4SO)-26

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Oil Catch Tank LUBRICATION

8. Oil Catch Tank A: REMOVAL For removal procedures, refer to IN (H4DOTC) section.

B: INSTALLATION For installation procedures, refer to IN (H4DOTC) section.

C: INSPECTION Refer to IN (H4DOTC) for inspection procedures.

LU(H4SO)-27

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Scavenge Pump LUBRICATION

9. Scavenge Pump

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. NOTE: Turbo model is equipped with scavenge pump. 1) Lift up the vehicle. 2) Remove the under cover. 3) Remove the union bolt (A) that holds the oil pipe (C) to the scavenge pump (E). 4) Remove the bolt (D) that holds the scavenge pump (E) to the cylinder head, and remove the scavenge pump using a flat tip screwdriver.

CAUTION: Do not start applying liquid gasket from (A) as shown in the following figure. NOTE: • Use a new gasket. • Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent (A)

CAUTION: Be careful not to damage the mating surface of the cylinder head and scavenge pump. LU-02602

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 29 N·m (3.0 kgf-m, 21.4 ft-lb)

(A) (B) (C)

T2 (E) (D)

(A) (B) (C) (D) (E)

(A) LU-02577

Union bolt Gasket Oil pipe BOLT Scavenge pump

(C)

(B)

T1 (E) (D)

(A) (B) (C) (D) (E)

LU-02578

Union bolt Gasket Oil pipe BOLT Scavenge pump

C: INSPECTION 1) Check that the scavenge pump and oil pipe have no deformation, cracks and other damages. 2) Check that the scavenge pump has no cracks, damage or loose part.

LU(H4SO)-28

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Oil Pipe LUBRICATION

10.Oil Pipe A: REMOVAL NOTE: Turbo model is equipped with oil pipe. 1) Remove the collector cover. 2) Disconnect the ground cable from battery.

CAUTION: In order to prevent damaging the oil inlet pipe, fix the section (a) shown in the figure when loosing the oil inlet pipe flare nut, and avoid the part from rotating together while loosening the nut.

(a)

EX-02549 IG-02107

3) Remove the intercooler. 4) Lift up the vehicle. 5) Remove the under cover. 6) Remove the ground cable from the oil outlet pipe. 7) Disconnect the oil outlet hose from the oil outlet pipe.

(C)

(B)

(A)

EX-02550

9) Lower the vehicle. 10) Remove the union bolt (B) which secures the oil outlet pipe (A) to the scavenge pump. 11) Remove the bolts (C) and (D) which secure the oil outlet pipe (A) to the cylinder head to remove the oil outlet pipe (A). (B)

EX-02548

(D)

8) Remove oil inlet pipe B (B) from oil inlet pipe A (A), and remove the bolt which holds oil inlet pipe C (C) and oil inlet pipe A (A).

(A)

A

A

(C)

LU-02585

LU(H4SO)-29

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Oil Pipe LUBRICATION

12) Remove the oil inlet pipe B (A) from the oil inlet pipe C (C). CAUTION: In order to prevent damaging the oil inlet pipe C (C), fix the section (a) shown in the figure when loosing the oil inlet pipe B (A) flare nut, and avoid the part from rotating together while loosening the nut.

18) Remove the timing belt cover. 19) Remove the timing belt.

20) Remove the cam sprocket LH. 21) Remove the belt cover No. 2 LH.

(a)

ME-04191 LU-02586

22) Remove the oil pipe.

13) Remove the bolt (B) which secures the oil inlet pipe B (A) to the cylinder head and the stay to remove the oil inlet pipe B (A). 14) Remove the union bolt (D) which secures the oil inlet pipe C (C) to the cylinder head to remove the oil inlet pipe C (C).

(A)

(B)

(C)

(D)

(D)

(D)

(B)

(C)

(A) (D)

(B) (C)

(B)

(D)

(A) (D) ME-04320

(A) (B) (C) (D) LU-02587

15) Remove the radiator main fan and radiator sub fan. 16) Remove the V-belts. 17) Remove the crank pulley.

LU(H4SO)-30

Union bolt with filter (with protrusion) Union bolt without filter (without protrusion) Oil pipe Gasket

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Oil Pipe LUBRICATION

B: INSTALLATION 1) Inspect the union bolt with filter. 2) Install the oil pipe. NOTE: • Be careful of the install location of the union bolt; the location will differ depending on the presence of filter. • Use a new gasket. (A)

(B)

(C)

(D)

(D)

(D)

NOTE: Use a new gasket.

(B) (C)

Tightening torque: 29 N·m (3.0 kgf-m, 21.4 ft-lb) 13) Temporarily tighten the oil inlet pipe B (A) to the oil inlet pipe C (C). 14) Secure the oil inlet pipe B (A) to the cylinder head with bolt (B).

(D)

(A) (D) ME-04320

(A) (B) (C) (D)

5) Install the timing belt. 6) Install the timing belt cover. 7) Install the crank pulley. 8) Install the V-belts. 9) Install the radiator main fan and the radiator sub fan. 10) Install the intake manifold. 11) Install the intercooler. 12) Attach the oil inlet pipe C (C) to the cylinder head with union bolt (D).

Union bolt with filter (with protrusion) Union bolt without filter (without protrusion) Oil pipe Gasket

3) Install the belt cover No. 2 LH.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 15) Tighten the flare nut of the oil inlet pipe B (A). CAUTION: In order to prevent damaging the oil inlet pipe C, fix the section (a) shown in the figure when tightening the oil inlet pipe B flare nut, and avoid the part from rotating together while tightening the nut.

(a)

LU-02586 ME-04191

4) Install the cam sprocket LH.

LU(H4SO)-31

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Oil Pipe LUBRICATION

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb)

Tightening torque: 29 N·m (3.0 kgf-m, 21.4 ft-lb)

(B)

(B)

(D) (C)

(A) (D)

(A)

(B) A

A

(C)

LU-02587

LU-02585

16) Temporarily tighten the oil outlet pipe (A) to the scavenge pump with union bolt (B). 17) Secure the oil outlet pipe (A) to the cylinder head and the stay with bolts (C) and (D).

19) Lift up the vehicle. 20) Install the bolt which holds oil inlet pipe C (C) and oil inlet pipe A (A), and install oil inlet pipe B (B) to oil inlet pipe A (A).

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 18) Tighten the union bolt (B) of the oil outlet pipe (A).

CAUTION: In order to prevent damaging the oil inlet pipe, fix the section (a) shown in the figure when tightening the oil inlet pipe flare nut, and avoid the part from rotating together while tightening the nut.

(a)

EX-02549

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Oil Pipe LUBRICATION

C: INSPECTION

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 20 N·m (2.0 kgf-m, 14.8 ft-lb)

(C)

1. INSPECTING UNION BOLT WITH FILTER Check the filter part of union bolt for clogging or damage, and if defective, replace the union bolt with filter with the new part.

T1

(A)

(B)

(C) (B)

T2

(D)

(D)

(D)

(A)

EX-02555

21) Attach the ground cable to the oil outlet pipe.

Tightening torque: T1: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) 22) Connect the oil outlet hose to the oil outlet pipe. (B) (C)

(D)

(A) (D) ME-04320 EX-02548

(A) (B) (C) (D)

23) Install the under cover. 24) Lower the vehicle. 25) Connect the ground cable to battery.

Union bolt with filter (with protrusion) Union bolt without filter (without protrusion) Oil pipe Gasket

2. OTHER INSPECTIONS 1) Check that the oil pipe and union bolt have no deformation, cracks and other damages. 2) Check that there are no oil leaks or oil oozing from the oil pipe attachment section.

IG-02107

26) Install the collector cover.

LU(H4SO)-33

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Engine Oil Filter LUBRICATION

11.Engine Oil Filter

B: INSTALLATION

A: REMOVAL

CAUTION: Do not tighten excessively, or oil may leak. 1) Clean the oil filter installation surface on cylinder block or engine oil cooler. 2) Obtain a new oil filter and apply a thin coat of engine oil to the seal rubber. 3) Install the oil filter turning it by hand, being careful not to damage the seal rubber of the oil filter. • Tighten the black oil filter (outer diameter of 68 mm (2.68 in)) by approx. 1 rotation after the seal rubber of the oil filter comes in contact with cylinder block. When using a torque wrench, tighten to 14 N·m (1.4 kgf-m, 10.3 ft-lb). • Tighten the blue oil filter (outer diameter of 67.4 mm (2.65 in)) by approx. 7/8 rotation after the seal rubber of the oil filter comes in contact with cylinder block. When using a torque wrench, tighten to 12 N·m (1.2 kgf-m, 8.9 ft-lb). 4) Return the service hole cover to its original position. (turbo model) 5) Lower the vehicle.

CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Lift up the vehicle. 2) Remove the service hole cover of under cover. • Medium under cover model

LU-02575

• Models with large under cover

C: INSPECTION 1) After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber.

LU-02570

NOTE: The filter element and filter case are permanently jointed; therefore, interior cleaning is not necessary. 2) Check the engine oil level.

3) Remove the oil filter. • Black oil filter Remove it using the ST. ST 18332AA000 OIL FILTER WRENCH (OUTER DIAMETER: 68 MM (2.68 IN) FOR OIL FILTER) • Blue oil filter Remove it using the general tool (65/67 mm 14 flutes).

LU-02576

LU(H4SO)-34

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Oil Level Switch LUBRICATION

12.Oil Level Switch

• Turbo model

A: REMOVAL 1) Disconnect the ground cable from battery.

IG-02107

2) Lift up the vehicle. 3) Remove the under cover. 4) Drain the engine oil. 5) Disconnect the connector of oil level switch from the engine harness. LU-02619

• 2.5 L non-turbo model

LU-02617

6) Remove the clip holding the oil level switch harness.

LU-02620

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Oil Level Switch LUBRICATION

7) Remove the oil level switch from cylinder block lower.

• 2.5 L non-turbo model

LU-02618

B: INSTALLATION 1) Install the oil level switch to cylinder block lower.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

LU-02620

3) Connect the connector of oil level switch to the engine harness.

LU-02618

2) Hold the oil level switch harness with clip. • Turbo model

LU-02617

4) Install the under cover. 5) Lower the vehicle. 6) Refill the engine oil. 7) Check the engine oil level. 8) Connect the ground cable to battery.

LU-02619 IG-02107

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Oil Level Switch LUBRICATION

C: WIRING DIAGRAM

TO POWER SUPPLY CIRCUIT FB-30 F/B FUSE NO. 5 (IG)

FB-17 F/B FUSE NO. 7 (B)

J/C

*

*

2

2

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 3, 4, 5 AND 6

*2 *3

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 7, 8, 9, 10, 11 AND 12 : NON-TURBO MODEL : 10 TURBO MODEL : 1

20

19

i82

*1

LOW ENGINE OIL WARNING LIGHT

COMBINATION METER

POWER SUPPLY CIRCUIT

I/F

i10

MICRO COMPUTER

DRIVE CIRCUIT

32

33

39

17

28

*1

CAN TRANSCEIVER & RECEIVER

J/C i 98

26

*1

B 1 3 6 ECM

B 21

*

3

OIL LEVEL SWITCH

E2

E 130

B21 i82 i98 1 2 3 4 5 6 7 8 9 10 11 12

B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

i10 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

LU-02653

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Oil Level Switch LUBRICATION

D: INSPECTION 1. INSPECTION WHILE OIL LEVEL SWITCH WARNING LIGHT IS ON 1

Step CHECK ENGINE OIL LEVEL.

Check Is engine oil level normal?

2

CHECK LAN SYSTEM.

Has a DTC of the LAN system Perform the diagnosis according to been input? DTC.

LU(H4SO)-38

Yes Go to step 2.

No Replace engine oil or refill, and check again while the oil level is normal condition. To turn off the oil level warning light, install the spare fuse at the delivery (test) mode fuse in the main fuse box. Then turn the ignition switch to ON (engine off) again, to confirm the warning light turns off. Remove the spare fuse installed to finish this step. NOTE: The engine oil level switch is normal, if the low engine oil level warning light turns off with the delivery (test) mode fuse installed. Go to step 3.

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Oil Level Switch LUBRICATION

3

4

5

Step Check CHECK OIL LEVEL SWITCH CIRCUIT. Is the “Oil level switch” signal 1) Turn the ignition switch to ON (engine OFF). displayed in Subaru Select 2) Read the current data for engine in the Sub- Monitor HIGH? aru Select Monitor to confirm the item for “Oil level switch”.

CHECK COMBINATION METER. Perform the self-diagnosis of combination meter to check if there are any faults in the combination meter. CHECK SECURE CONNECTION OF CONNECTOR BETWEEN ENGINE HARNESS AND OIL LEVEL SWITCH.

Is the combination meter normal?

Is there any insecure connection?

LU(H4SO)-39

Yes No To turn off the oil Go to step 4. level warning light, install the spare fuse at the delivery (test) mode fuse in the main fuse box. Then turn the ignition switch to ON (engine off) again, to confirm the warning light turns off. Remove the spare fuse installed to finish this step. NOTE: The engine oil level switch is normal, if the low engine oil level warning light turns off with the delivery (test) mode fuse installed. Go to step 5. Replace the combination meter.

Remedy the con- Go to step 6. nection condition. Then, to turn off the oil level warning light, install the spare fuse at the delivery (test) mode fuse in the main fuse box. Then turn the ignition switch to ON (engine off) again, to confirm the warning light turns off. Remove the spare fuse installed to finish this step. NOTE: The engine oil level switch is normal, if the low engine oil level warning light turns off with the delivery (test) mode fuse installed.

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Oil Level Switch LUBRICATION

6

7

8

Step CHECK OIL LEVEL SWITCH. 1) Deliberately short circuits by connecting the engine harness connector terminal and chassis ground. 2) Turn the ignition switch to ON (engine OFF). 3) Read the current data for engine in the Subaru Select Monitor to confirm the item for “Oil level switch”. Connector & terminal (E130) No. 1 — Chassis ground: CHECK SECURE CONNECTION OF CONNECTOR BETWEEN BULKHEAD HARNESS AND ENGINE HARNESS.

Check Is the “Oil level switch” signal displayed in Subaru Select Monitor HIGH?

Is there any insecure connection?

Yes No Replace the oil Go to step 7. level switch.

Remedy the con- Go to step 8. nection condition. Then, to turn off the oil level warning light, install the spare fuse at the delivery (test) mode fuse in the main fuse box. Then turn the ignition switch to ON (engine off) again, to confirm the warning light turns off. Remove the spare fuse installed to finish this step. NOTE: The engine oil level switch is normal, if the low engine oil level warning light turns off with the delivery (test) mode fuse installed. CHECK ENGINE HARNESS. Is the resistance less than 1 Ω? Go to step 9. Repair or replace 1) Disconnect the oil level switch side connecthe open circuit of tor of the engine harness. engine harness. 2) Disconnect the bulkhead harness side connector of the engine harness. 3) Measure the resistance between connector terminals. Connector & terminal • Non-turbo model (E2) No. 10 — (E130) No. 1: • Turbo model (E2) No. 1 — (E130) No. 1:

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Oil Level Switch LUBRICATION

9

10

Step Check CHECK SECURE CONNECTION OF CONIs there any insecure connecNECTOR BETWEEN ENGINE CONTROL tion? MODULE (ECM) AND BULKHEAD HARNESS. Remove the glove box lid assembly.

Yes Remedy the connection condition. Then, to turn off the oil level warning light, install the spare fuse at the delivery (test) mode fuse in the main fuse box. Then turn the ignition switch to ON (engine off) again, to confirm the warning light turns off. Remove the spare fuse installed to finish this step. NOTE: The engine oil level switch is normal, if the low engine oil level warning light turns off with the delivery (test) mode fuse installed. Is the resistance less than 1 Ω? Replace the Engine Control Module (ECM).

No Go to step 10.

CHECK BULKHEAD HARNESS. 1) Remove the glove box lid assembly. 2) Disconnect the engine control module (ECM) side connector of the bulkhead harness. 3) Disconnect the engine harness connectors of the bulkhead harness. 4) Measure the resistance between connector terminals. Connector & terminal • Non-turbo model (B136) No. 26 — (B21) No. 10: • Turbo model (B136) No. 26 — (B21) No. 1:

Repair or replace the open circuit of bulkhead harness.

2. OTHER INSPECTIONS 1) Check that the oil level switch does not have deformation, cracks, or damage. 2) Check the oil level switch installation part for oil leakage and oil seepage.

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Engine Lubrication System Trouble in General LUBRICATION

13.Engine Lubrication System Trouble in General A: INSPECTION Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists. Trouble

Warning light remains ON.

Warning light does not illuminate.

Warning light flickers momentarily.

Possible cause a. Oil pressure switch failure Cracked diaphragm or oil leakage within switch Broken spring or seized contacts b. Low oil pressure Clogging of oil filter Malfunction of oil by-pass valve in oil filter Malfunction of oil relief valve in oil pump Clogged oil passage Excessive tip clearance and side clearance of oil pump rotor Clogged oil strainer or broken pipe c. No oil pressure Insufficient engine oil (degradation, etc.) Broken pipe of oil strainer Stuck oil pump rotor a. Defective combination meter b. Poor contact of switch contact points c. Disconnection of wiring a. Defective terminal contact b. Defective wiring harness c. Oil pressure switch failure Cracked diaphragm or oil leakage within switch Broken spring or seized contacts d. Low oil pressure Clogging of oil filter

Corrective action Replace. Replace. Replace. Replace. Clean or replace. Clean. Replace. Clean or replace. Replace. Replace. Replace. Replace. Replace. Repair. Repair. Repair. Replace. Replace. Replace.

Malfunction of oil by-pass valve in oil filter Malfunction of oil relief valve in oil pump Clogged oil passage Excessive tip clearance and side clearance of oil pump

Replace. Clean or replace. Clean.

Clogged oil strainer or broken pipe

Clean or replace.

rotor

LU(H4SO)-42

Replace.

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SPEED CONTROL SYSTEMS

SP(H4SO) 1. 2.

Page General Description ...................................................................................2 Accelerator Pedal .......................................................................................4

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General Description SPEED CONTROL SYSTEMS

1. General Description A: SPECIFICATION Accelerator pedal

Stroke

At pedal pad

54 — 59 mm (2.13 — 2.32 in)

B: COMPONENT

(2) (1)

T

T (4) (3)

SP-02085

(1) (2)

Accelerator pedal ASSY Clip

(3) (4)

Accelerator plate Accelerator stopper

Tightening torque:N·m (kgf-m, ft-lb) T: 18 (1.8, 13.3)

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal or installation. • Keep the parts in order and protect them from dust and dirt. • Before removal or installation, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.

SP(H4SO)-2

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General Description SPEED CONTROL SYSTEMS

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 1B022XU0

DESCRIPTION SUBARU SELECT MONITOR III KIT

REMARKS Used for inspecting the accelerator pedal.

ST1B022XU0

2. GENERAL TOOL TOOL NAME Circuit tester

REMARKS Used for measuring voltage.

SP(H4SO)-3

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Accelerator Pedal SPEED CONTROL SYSTEMS

2. Accelerator Pedal

D: INSPECTION

A: REMOVAL

1. CHECK ACCELERATOR PEDAL SENSOR AREA (METHOD WITH CIRCUIT TESTER)

1) Disconnect the ground cable from battery.

1) Remove the glove box lid assembly, glove box lower cover, instrument panel side cover RH and glove box back panel. 2) Turn the ignition switch to ON. (engine OFF) 3) Check the voltage between ECM connector terminals. IG-02107

2) Disconnect the connector (A). 3) Remove the nut (B) securing accelerator pedal assembly and remove the accelerator pedal assembly. (A) FU-04956

Main sensor side (A) 7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 31 30 29 28 35 34 33 32

V SP-02078

(B)

Sub sensor side (A)

SP-02086

7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 31 30 29 28 35 34 33 32

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

V SP-02079

C: DISASSEMBLY

(A) To ECM connector

NOTE: The accelerator pedal cannot be disassembled.

SP(H4SO)-4

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Accelerator Pedal SPEED CONTROL SYSTEMS Accelerator pedal sensor

Main

Accelerator pedal Not depressed (Full closed)

Sub

Depressed (Full opened) Not depressed (Full closed) Depressed (Full opened)

Terminal No.

23 (+) and 29 (–)

Standard 0.4 — 1.0 V 2.4 — 3.7 V

31 (+) and 30 (–)

0.3 — 1.1 V 2.3 — 3.8 V

4) After inspection, install the related parts in the reverse order of removal.

2. CHECK ACCELERATOR PEDAL SENSOR AREA (METHOD WITH SUBARU SELECT MONITOR) 1) Turn the ignition switch to ON. (engine OFF) 2) Read the accelerator pedal opening angle signal and voltage of accelerator pedal sensor using Subaru Select Monitor. Accelerator pedal sensor Main Sub

Accelerator pedal opening angle signal

Standard

0.0% 100.0% 0.0% 100.0%

0.4 — 1.0 V 2.4 — 3.7 V 0.3 — 1.1 V 2.3 — 3.8 V

3. OTHER INSPECTIONS 1) Check that the accelerator pedal does not have deformation, cracks or damage. 2) Check for smooth operation when the accelerator pedal is depressed. 3) Check if the accelerator pedal returns to its original position smoothly when the pedal is released.

SP(H4SO)-5

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Accelerator Pedal SPEED CONTROL SYSTEMS

SP(H4SO)-6

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IGNITION

IG(H4SO) 1. 2. 3.

Page General Description ...................................................................................2 Spark Plug ..................................................................................................3 Ignition Coil ................................................................................................5

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General Description IGNITION

1. General Description A: SPECIFICATION Item Ignition coil and ignitor ASSY

Spark plug

Type Ignition system Manufacturer Manufacturer and type Thread size (diameter, pitch, length) Spark plug gap Electrode

SPECIFICATION FK 0376 Independent ignition coil Diamond Electric NGK: SIFR6A11 14,1.25,19 1.0 — 1.1 (0.039 — 0.043) Iridium

mm mm (in) Standard

B: COMPONENT T1

T2 (1) (2)

T1

T2 (1)

(2)

IG-02103

(1)

Spark plug

(2)

Ignition coil

Tightening torque:N·m (kgf-m, ft-lb) T1: 9 (0.9, 6.6) T2: 21 (2.1, 15.5)

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.

IG(H4SO)-2

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Spark Plug IGNITION

2. Spark Plug

3) Remove the bolt (B), and remove the ignition coil.

A: REMOVAL Spark plug: Refer to “SPECIFICATION” for the spark plug.

(B)

1. RH SIDE

(B)

(A)

1) Disconnect the ground cable from battery.

(A)

IG-02105

4) Remove the spark plug with a spark plug socket.

B: INSTALLATION 1. RH SIDE Install in the reverse order of removal.

Tightening torque (Spark plug): 21 N·m (2.1 kgf-m, 15.5 ft-lb)

IG-02107

2) Remove the air cleaner case. 3) Disconnect the connector (A) from ignition coil. 4) Remove the bolt (B), and remove the ignition coil.

2. LH SIDE Install in the reverse order of removal.

Tightening torque (Spark plug): 21 N·m (2.1 kgf-m, 15.5 ft-lb)

(B)

(B)

Tightening torque (Ignition coil): 9 N·m (0.9 kgf-m, 6.6 ft-lb)

Tightening torque (Ignition coil): 9 N·m (0.9 kgf-m, 6.6 ft-lb)

C: INSPECTION (A)

1) Check the spark plug for abnormalities. If defective, replace the spark plug.

(A) IG-02104

(C)

5) Remove the spark plug with a spark plug socket.

2. LH SIDE 1) Disconnect the ground cable from battery. (A) (B)

IG-02094

(A) Terminal damage (B) Crack or damage in insulator (C) Damaged gasket IG-02107

2) Disconnect the connector (A) from ignition coil.

2) Check the spark plug electrode and condition of the insulator. If abnormal, check and repair the cause and replace the spark plug.

IG(H4SO)-3

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Spark Plug IGNITION

(1) Normal: Brown to grayish-tan deposits and slight electrode wear indicate correct spark plug heat range.

(4) Overheating: White or light gray insulator with black or brown spots and bluish burnt electrodes indicate engine overheating, wrong selection of fuel, or loose spark plugs.

IG-00011

(2) Carbon fouled: Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in the city, weak ignition, too rich fuel mixture, etc.

IG-00014

3) Using a nylon brush, etc., clean and remove the carbon or oxide deposits from the spark plug. If deposits are too stubborn, replace the spark plugs. After cleaning the spark plugs, check the spark plug gap “L” using a gap gauge. If it is not within the standard, replace the spark plug. NOTE: • Never use a plug cleaner. • Do not use a metal brush as it may damage the electrode area.

Spark plug gap L: Standard 1.0 — 1.1 mm (0.039 — 0.043 in)

IG-00012

(3) Oil fouled: Wet black deposits show oil entrance into combustion chamber through worn piston rings or increased clearance between valve guides and valve stems.

L

IG-02108

IG-00013

IG(H4SO)-4

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Ignition Coil IGNITION

3. Ignition Coil A: REMOVAL Direct ignition type is adopted. Refer to “Spark Plug” for removal procedure.

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 9 N·m (0.9 kgf-m, 6.6 ft-lb)

C: INSPECTION For inspection procedure, refer to “Diagnostics for Engine Starting Failure”.

IG(H4SO)-5

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Ignition Coil IGNITION

IG(H4SO)-6

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STARTING/CHARGING SYSTEMS

SC(H4SO) 1. 2. 3. 4.

Page General Description ...................................................................................2 Starter ........................................................................................................9 Generator .................................................................................................18 Battery ......................................................................................................26

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General Description STARTING/CHARGING SYSTEMS

1. General Description A: SPECIFICATION 1. 2.5 L MODEL Item

SPECIFICATION

Vehicle model

AT and CVT Type Model Manufacturer Voltage and output Direction of rotation Number of pinion teeth

No-load characteristics Starter

Load characteristics

Lock characteristics

428000-4790

Voltage Current Rotating speed

11 V 90 A or less 1,900 rpm or more

Voltage Current Torque Rotating speed

8V 370 A 11.1 N·m (1.1 kgf-m, 8.2 ft-lb) or more

Voltage Current Torque

3V 750 A or less 15.5 N·m (1.6 kgf-m, 11.4 ft-lb) or more Rotating-field three-phase type, voltage regulator built-in type, with load response control system A3TG6191 Mitsubishi Electric 12 V — 110 A Negative Clockwise (when observed from pulley side) 3-phase Y-type 1,500 rpm — 50 A or more 2,500 rpm — 91 A or more 5,000 rpm — 105 A or more 14.1 — 14.8 V [20°C (68°F)] 22.7 mm (0.894 in)

Model Manufacturer Voltage and output Polarity on ground side Direction of rotation Armature connection Output current Regulated voltage

Battery

428000-4780

DENSO 12 V — 1.4 kW Counterclockwise (when observed from pinion) 9

Type

Generator

MT Reduction type

Outer diameter of rotor slip ring

Standard Service limit

Brush length

Standard Service limit

910 rpm or more

22.1 mm (0.870 in) 18.5 mm (0.728 in) 5.0 mm (0.197 in)

Type and capacity

12 V — 52 AH (75D 23R)

SC(H4SO)-2

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General Description STARTING/CHARGING SYSTEMS

2. 3.6 L MODEL Item Vehicle model Type Model Manufacturer Voltage and output Direction of rotation Number of pinion teeth

No-load characteristics Starter

Load characteristics

Lock characteristics

Voltage Current Rotating speed

8V 370 A 12.8 N·m (1.3 kgf-m, 9.4 ft-lb) or more

Voltage Current Torque

3V 750 A or less 19.0 N·m (1.9 kgf-m, 14.0 ft-lb) or more

Model Manufacturer Voltage and output Polarity on ground side Direction of rotation Armature connection Output current Regulated voltage

Battery

1,550 rpm or more

Voltage Current Torque Rotating speed

Type

Generator

SPECIFICATION AT Reduction type 428000-5250 DENSO 12 V — 1.6 kW Counterclockwise (when observed from pinion) 9 11 V 90 A or less

Outer diameter of rotor slip ring

Standard Service limit

Brush length

Standard Service limit

800 rpm or more

Rotating-field three-phase type, voltage regulator built-in type, with load response control system A3TJ3591 Mitsubishi Electric 12 V — 130 A Negative Clockwise (when observed from pulley side) 3-phase type 1,500 rpm — 55 A or more 2,500 rpm — 108 A or more 5,000 rpm — 127 A or more 14.1 — 14.8 V [20°C (68°F)] 22.7 mm (0.894 in) 22.1 mm (0.870 in) 18.5 mm (0.728 in) 5.0 mm (0.197 in)

Type and capacity

12 V — 52 AH (75D 23R)

SC(H4SO)-3

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General Description STARTING/CHARGING SYSTEMS

B: COMPONENT 1. STARTER T4 (18)

(10) (11) (9)

(7)

T2 (6) (5)

T3

(3)

(8) (4)

(16) (15)

T1

(2)

(17) (14) (19) (13)

(1)

(12)

SC-02127

(1) (2)

Starter housing Snap ring

(10) (11)

Internal gear Shaft

(19)

(3) (4) (5) (6) (7) (8) (9)

Stopper Overrunning clutch Snap ring Shift lever Starter seal Shock absorber bearing Shock absorber

(12) (13) (14) (15) (16) (17) (18)

Planetary gear Starter plate Yoke Armature Brush holder ASSY Starter cover Magnet switch ASSY

Tightening torque:N·m (kgf-m, ft-lb) T1: 1.4 (0.1, 1.0) T2: 6 (0.6, 4.4) T3: 7.5 (0.8, 5.5) T4: 10 (1.0, 7.4)

SC(H4SO)-4

Drain duct

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General Description STARTING/CHARGING SYSTEMS

2. GENERATOR • 2.5 L model (7)

(6)

(5) (4) (3) T1 (2)

(1)

T1

T2 (13)

(12)

(11) (10) (9)

(8) SC-02121

(1) (2) (3) (4) (5) (6)

Pulley nut Pulley Front cover Ball bearing Bearing retainer Rotor

(7) (8) (9) (10) (11) (12)

Bearing STATOR COIL IC regulator with brush Brush Rectifier Rear cover

SC(H4SO)-5

(13)

Terminals

Tightening torque:N·m (kgf-m, ft-lb) T1: 4.7 (0.5, 3.5) T2: 108 (11.0, 79.8)

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General Description STARTING/CHARGING SYSTEMS

• 3.6 L model (8)

(7) (6) (5) (4) (3) T1 (2)

(1) T5

T2

T3 (14)

T2 (13)

(12)

T4

(11) (10) T4 (9) SC-02298

(1) (2) (3) (4) (5) (6) (7)

Pulley nut Pulley Front cover Ball bearing Bearing retainer SPACER Rotor

(8) (9) (10) (11) (12) (13) (14)

Bearing STATOR COIL IC regulator Brush Rectifier Rear cover Terminal B

SC(H4SO)-6

Tightening torque:N·m (kgf-m, ft-lb) T1: 4.4 (0.4, 3.2) T2: 3.9 (0.4, 2.9) T3: 117.5 (12.0, 86.7) T4: 2 (0.2, 1.5) T5: 8.9 (0.9, 6.6)

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General Description STARTING/CHARGING SYSTEMS

3. GENERATOR BRACKET

(5)

T2

(6)

(4)

(3)

(7)

T4

T3

(2)

(1)

T4 (8)

T5

T1

SC-02376

(1) (2) (3) (4)

V-belt cover bracket Collector cover bracket V-belt tensioner ASSY Power steering pump bracket

(5) (6) (7) (8)

Generator Generator plate A/C compressor bracket Idler pulley

SC(H4SO)-7

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 16 (1.6, 11.8) T3: 20 (2.0, 14.8) T4: 25 (2.5, 18.4) T5: 33 (3.4, 24.3)

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General Description STARTING/CHARGING SYSTEMS

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.

SC(H4SO)-8

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Starter STARTING/CHARGING SYSTEMS

2. Starter

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal. NOTE: For the MT model, a bolt is used in place (A).

1) Disconnect the ground cable from battery.

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb) (A)

IG-02107

2) Remove the air intake boot assembly. (non-turbo model) 3) Remove the intercooler. (turbo model) 4) Disconnect connector (B) and terminal (A) from starter.

SC-02363

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb)

SC-00006

C: DISASSEMBLY SC-00006

5) Remove the starter from transmission. NOTE: For the MT model, a bolt is used in place (A).

1) Remove the nut which holds terminal M (A) of the magnet switch assembly, then disconnect the harness from the terminal.

(A) (A)

SC-02128 SC-02363

SC(H4SO)-9

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Starter STARTING/CHARGING SYSTEMS

2) Remove the nuts fastening the magnet switch assembly to the starter housing, then remove the magnet switch assembly.

5) Remove the shift lever.

SC-02133 SC-02129

6) Remove the overrunning clutch, shock absorber bearing, and shaft from the yoke as a single unit

3) Remove the starter seal.

SC-02130

4) Remove the through bolts on both sides, and remove the starter housing.

SC-02136

SC-02131

7) Use the following procedures to remove the overrunning clutch from the shaft assembly.

SC-02132

SC(H4SO)-10

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Starter STARTING/CHARGING SYSTEMS

(1) Use an appropriate tool (such as a fit socket wrench), remove the stopper from snap ring by lightly tapping the stopper with a plastic hammer.

(3) Remove the overrunning clutch from the shaft.

(A)

(B) (D) (C) SC-02135

8) Remove the shock absorber in the following procedures: (1) Remove the starter plate.

SC-02148

(A) (B) (C) (D)

Appropriate tool Snap ring Shaft STOPPER

SC-02138

(2) Remove the planetary gear.

(2) Remove snap ring (A) from the shaft, and remove stopper (B).

(A) SC-02139 (B)

SC-02134

SC(H4SO)-11

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Starter STARTING/CHARGING SYSTEMS

(3) Remove the snap ring, then remove the shaft.

NOTE: Separate the starter cover by pressing the brush holder assembly using the screws so that the assembly stays onto the armature side.

SC-02137 SC-02142

SC-02140

(4) Separate shock absorber bearing (A) from internal gear (B), and remove shock absorber (C). (A)

SC-02143

10) Remove the brush holder assembly from the armature. NOTE: Expand the brush with your fingers while taking care not to scratch it.

(B)

(C) SC-02141

9) Remove the screws, and remove the starter cover from the brush holder assembly. SC-02144

11) Remove the armature from the yoke.

SC-02145

SC(H4SO)-12

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Starter STARTING/CHARGING SYSTEMS

D: ASSEMBLY

Grease: DENSO HL50

1) Install the armature to the yoke.

(A)

(B)

(C) SC-02141

SC-02145

2) Install the brush holder assembly to the armature. NOTE: Expand the brush with your fingers while taking care not to scratch it.

(2) Assemble the shaft to the internal gear. NOTE: Apply grease to the shaft sliding surfaces inside the internal gear.

Grease: DENSO HL50

SC-02144

3) Install the starter cover, and secure it to the brush holder assembly with the screws.

SC-02140

(3) Attach the snap ring to the shaft. NOTE: Use new snap rings.

SC-02142

4) Assemble the shock absorber in the following procedures: (1) Apply grease to shock absorber (C), and assemble internal gear (B) to shock absorber bearing (A). NOTE: Align with the claw position of internal gear to assemble the shock absorber bearing.

SC-02137

5) Assemble the planetary gear to the internal gear. (1) Apply grease to the planetary gear installation position.

Grease: DENSO HL50 (2) Install the planetary gear to the pin. (3) Apply grease to the planetary gear, internal gear, and upper part of the pin.

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Starter STARTING/CHARGING SYSTEMS

NOTE: • Apply grease so that it contact surfaces of each gear. • Be careful not to allow dirt to get in.

(3) Install stopper (B) to the shaft, then install snap ring (A).

Grease: DENSO HL50

(A)

(B)

SC-02134

(4) Using a press, pressure fit stopper (B) into snap ring (A). (A)

SC-02139

(4) Install the starter plate.

(B)

SC-00068

7) Assemble the overrunning clutch, shock absorber, and shaft to the yoke as a single unit SC-02138

6) Assemble the overrunning clutch as follows: (1) Apply grease to the spline portion of the shaft.

Grease: DENSO HL50 (2) Install the overrunning clutch to shaft.

SC-02135

SC-02136

8) Install the shift lever. NOTE: Apply grease to the contact area of the shift lever.

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Starter STARTING/CHARGING SYSTEMS

Grease: DENSO HL50

Grease: DENSO HL50 Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

SC-02133

9) Install the starter housing, and tighten through bolts on both sides.

Tightening torque: 6 N·m (0.6 kgf-m, 4.4 ft-lb)

SC-02129

12) Install the harness to the terminal M (A) of the magnet switch assembly, and tighten the nut.

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb)

(A)

SC-02132

SC-02128

SC-02131

10) Install the starter seal.

SC-02130

11) Install the magnet switch assembly to the starter housing, and tighten the nuts. NOTE: Apply grease to the shift lever installation position.

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Starter STARTING/CHARGING SYSTEMS

E: INSPECTION

2) Holding test Check that the pinion gear remains flying out after the cable is disconnected from terminal M.

1. SWITCH ASSEMBLY Using a circuit tester (set to “ohm”), check that there is continuity between terminals S and M, and between terminal S and ground. Also check to be sure there is no continuity between terminals M and B.

(B)

Terminal/Resistance: S — M/1 Ω or less S — Ground/1 Ω or less M — B/1 MΩ or more

(A) SC-02087

(A) Terminal S (B) Terminal M

(C)

(A) (B) SC-00181

3) Returning test With terminal S connected to the positive terminal, and terminal M and starter body connected to the battery ground terminal to suction the main contact point, check that the pinion gear returns to its original position when terminal S is disconnected.

(A) Terminal S (B) Terminal M (C) Terminal B

(B)

2. SWITCH ASSEMBLY OPERATION NOTE: Perform each test in a short period of time (3 — 5 sec). 1) Suction test Check that the pinion gear comes flying out when the harness is disconnected from terminal M and connected as shown in the figure.

(A) SC-02088

(A) Terminal S (B) Terminal M

3. PERFORMANCE TEST (B)

(A) SC-02086

The starter should be submitted to performance tests whenever it has been overhauled, to assure its satisfactory performance when installed on the engine. Three performance tests, no-load test, load test, and lock test, are presented here; however, if the load test and lock test cannot be performed, carry out at least the no-load test.

(A) Terminal S (B) Terminal M

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Starter STARTING/CHARGING SYSTEMS

For these performance tests, use the circuit shown in figure.

S

B

(B)

Torque 2.5 L model 15.5 N·m (1.6 kgf-m, 11.4 ft-lb) 3.6 L model 19.0 N·m (1.9 kgf-m, 14.0 ft-lb)

(A)

M +

(C)

12V V

A SC-00077

(A) Variable resistance (B) Magnetic switch (C) Starter body

1) No-load test Adjust the variable resistance with the switch on until the voltage is 11 V, and read the value displayed on the ammeter to measure rotating speed. Compare these values with the standard.

No-load test (standard): Voltage/Current Max. 11 V/90 A or less Rotating speed 2.5 L model 1,900 rpm or more 3.6 L model 1,550 rpm or more 2) Load test Apply the specified braking torque to starter. The condition is normal if the current draw and rotating speed are within standard. Load test (standard): Voltage/Load 2.5 L model 8 V/11.1 N·m (1.1 kgf-m, 8.2 ft-lb) 3.6 L model 8 V/12.8 N·m (1.3 kgf-m, 9.4 ft-lb) Current/Rotating speed 2.5 L model 370 A/910 rpm or more 3.6 L model 370 A/800 rpm or more 3) Lock test With the starter stalled, or not rotating, measure the torque developed and current draw when the voltage is adjusted to standard voltage. Lock test (standard): Voltage/Current 3 V/750 A or less

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Generator STARTING/CHARGING SYSTEMS

3. Generator

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Disconnect the ground cable from battery.

Tightening torque: T1: 25 N·m (2.5 kgf-m, 18.4 ft-lb) T2: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

T1

T2

IG-02107

2) Remove the V-belts.

3) Disconnect the connector and terminal from generator.

SC-02374

C: DISASSEMBLY 1. 2.5 L MODEL 1) Remove the four through bolts.

SC-00078

SC-02372

4) Remove the collector cover bracket or v-belt cover bracket.

2) Use a drier to heat the rear cover (A) portion to 50°C (122°F). (A)

SC-02373

5) Remove the generator from the bracket.

SC-02375

SC(H4SO)-18

SC-00079

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Generator STARTING/CHARGING SYSTEMS

3) Insert the end of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

(1) Remove the bolt, and then detach the bearing retainer.

(A)

(A) SC-00081 SC-00080

(A) Screwdriver

(2) Firmly attach an appropriate tool (such as a correct size socket wrench) to the bearing inner race.

4) Using a vise, support the rotor and remove the pulley bolt.

SC-00082

SC-00035

CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.

(3) Use the press to push the ball bearings out from the front cover. 6) Using the bearing puller, remove the bearings from the rotor.

(A) (B)

SC-00046 (C) (D)

(A) (B) (C) (D)

SC-00036

7) Disconnect the connection between the rectifier and stator coil, then remove the stator coil.

Front cover Pulley Nut Rotor

5) Use the following procedures to remove the ball bearings.

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Generator STARTING/CHARGING SYSTEMS

CAUTION: The rectifier is easily damaged by heat. Do not allow a 180 — 270 W soldering iron to contact the terminals for 5 seconds or more at a time.

(1) Remove the cover A. (A)

SC-00086

(A) Cover A SC-00083

8) Use the following procedures to remove the IC regulator. (1) Remove the screws which secure the IC regulator to the rear cover.

(2) Remove the cover B. (A)

SC-00087

(A) Cover B SC-00084

(2) Disconnect the connection between the IC regulator and rectifier, then remove the IC regulator.

(3) Disconnect the connection and remove the brush.

SC-00088

SC-00085

10) Remove the rectifier as follows. (1) Remove the bolts which secure the rectifier.

9) Use the following procedures to remove the brush.

SC-00089

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Generator STARTING/CHARGING SYSTEMS

(2) Remove the cover on terminal B.

3) Insert the end of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

(A)

(A)

SC-00090

(3) Remove the nuts of terminal B, then remove the rectifier.

SC-00080

(A) Screwdriver

4) Using a vise, support the rotor and remove the pulley bolt.

SC-00091

2. 3.6 L MODEL 1) Remove the four through bolts. SC-00035

CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage. (A) (B) SC-00078

2) Use a drier to heat the rear cover (A) portion to 50 — 60°C (122 — 140°F). (C)

(A)

(D) SC-02300

(A) (B) (C) (D) SC-02299

Front cover Pulley Nut Rotor

5) Use the following procedures to remove the ball bearings.

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Generator STARTING/CHARGING SYSTEMS

(1) Remove the bolt, and then detach the bearing retainer.

8) Remove four screws which secure the IC regulator to the rear cover, then remove the IC regulator.

SC-00081

(2) Firmly attach an appropriate tool (such as a correct size socket wrench) to the bearing inner race.

SC-02302

9) Use the following procedures to remove the brush. (1) Remove the cover A. (A)

SC-00082

(3) Use the press to push the ball bearings out from the front cover. 6) Using the bearing puller, remove the bearings from the rotor.

SC-02303

(A) Cover A

(2) Remove the cover B. (A)

SC-00046

SC-02304

7) Remove six bolts between the rectifier and stator coil, then remove the stator coil.

(A) Cover B

(3) Disconnect the connection and remove the brush.

SC-02301

SC-02305

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Generator STARTING/CHARGING SYSTEMS

D: ASSEMBLY

10) Remove the rectifier as follows. (1) Remove the cover on terminal B.

Assemble in the reverse order of disassembly.

SC-02307

(2) Remove the nut on terminal B.

NOTE: Refer to component for tightening torque of each part. 1) Push of the brush Before assembling the front and rear parts, press the brush down into the brush holder, then fix the brush in that position by inserting a [1 mm (0.08 in) dia., 40 — 50 mm (1.6 — 2.0 in) long] wire through the hole as shown in the figure. CAUTION: After re-assembling, remove the wire. (A)

SC-02308

(3) Remove the bolts which secure the rectifier, and remove the rectifier.

SC-02306

SC-00092

(A) Wire

2) Install the ball bearings. (1) Set the ball bearings in the front cover, then securely install an appropriate tool (such as a socket wrench of proper size) to the bearing outer race. (2) Using a press to press the ball bearings into the specified location. (3) Install the bearing retainer. 3) Use a press to install the bearings (rear side) to the rotor shaft. 4) Heat the bearing box in rear cover to 50 — 60°C (122 — 140°F), and then press the rear bearing into rear cover. CAUTION: Do not apply grease to the rear bearings. If there is any oil on the bearing box, remove it completely. 5) After re-assembling, manually turn the pulley to check that the rotor rotates smoothly.

SC(H4SO)-23

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Generator STARTING/CHARGING SYSTEMS

E: INSPECTION 1. DIODE CAUTION: There is the possibility of damaging the diodes if a mega-tester (used to measure high voltages) or a similar measuring instrument is used. Never use a mega tester or equivalent for this test. 1) Check for continuity between the diode lead and terminal E or B. If continuity is not as shown in the table, replace the rectifier. • At analog type tester Tester lead –lead E

+lead P1, P2, P3, P4, P5, P6

Yes No

P1, P2, P3, P4, P5, P6

E B

No Yes

SC-00044

4) Insulation test Check the continuity between slip ring and rotor core or shaft. If there is continuity, replace the rotor assembly because the rotor coil is grounded.

• At digital type tester Tester lead +lead

Continuity

B

P1, P2, P3, P4, P5, P6

No Yes

P1, P2, P3, P4, P5, P6

E B

Yes No

P5

P4 P3

Specified resistance: Approximately 2.0 — 2.3 Ω

Continuity

B

–lead E

3) Continuity test Using a circuit tester, check the resistance between slip rings. If the resistance is not within the standard, replace the rotor assembly.

P6

SC-00045

5) Bearing (rear side) Check the bearing (rear side). If there is any noise, or the rotor does not rotate smoothly, replace the bearings.

P2 P1 E B

SC-02310

2. ROTOR 1) Slip ring surface Inspect the slip rings for contamination or any roughness on the sliding surface. Repair the slip ring surface using a lathe or sand paper. 2) Slip ring outer diameter Measure the slip ring outer diameter. Replace the rotor assembly if the slip ring is worn.

Slip ring outer diameter: Standard 22.7 mm (0.894 in) Service limit 22.1 mm (0.870 in)

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Generator STARTING/CHARGING SYSTEMS

3. STATOR COIL

4. BRUSH

1) Continuity test Inspect the continuity between the stator coil terminals. If continuity is not as shown in the table, replace the stator coil.

1) Measure the length of each brush. Replace the brush if wear exceeds service limits. There is a service limit mark (A) on each brush.

(A)

1

2

3

4

5

6

Brush length: Standard (1) 22.5 mm (0.886 in) Service limit (2) 5.0 mm (0.197 in) (2) (A)

SC-02349

(1)

(A) Terminals

2 1

3 4

SC-02313 5 6

SC-02311

2) Check that there is appropriate pressure on the brush spring. Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.08 in). Then measure the pressure of brush spring. If the pressure is 1.7 N (173 gf, 6.11 ozf) or less, replace the brush spring. 4.1 — 5.3 N (418 — 540 gf, 14.75 — 19.06 ozf) pressure is required on the new spring.

2) Insulation test Inspect the continuity between the stator coil stator core and lead wire terminals. If there is continuity, replace the stator coil because the stator coil is grounded.

SC-02312

5. BALL BEARING (FRONT SIDE) Check the ball bearings. Replace the ball bearings if there is resistance in the rotation, or if there is any abnormal noise. SC-02314

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Battery STARTING/CHARGING SYSTEMS

4. Battery A: REMOVAL 1) After disconnecting the battery ground terminal, remove the terminal cover, then disconnect the positive terminal. 2) Remove the battery cable holder from the battery rod. 3) Remove flange nut from the battery rod and remove battery holder.

• Ventilate sufficiently when using or charging battery in enclosed space. • Before starting work, remove rings, metal watch-bands, and other metal jewelry. • Never allow metal tools to contact the positive battery terminal and anything connected to it while you are at the same time in contact with any other metallic portion of the vehicle.

1. EXTERNAL PARTS Check the battery case, top cover, vent plugs, and terminal posts for dirt or cracks. If necessary, clean with water and wipe with a dry cloth. Apply a thin coat of grease on the terminal posts to prevent corrosion.

2. ELECTROLYTE LEVEL

SC-02377

Check the electrolyte level in each cell. If the level is below MIN level, bring the level to MAX level by pouring distilled water into the battery cell. Do not fill beyond MAX level.

4) Remove the battery.

3. SPECIFIC GRAVITY OF ELECTROLYTE

B: INSTALLATION

1) Measure specific gravity of electrolyte using a hydrometer and a thermometer. Specific gravity varies with temperature of electrolyte so that it must be corrected at 20°C (68°F) using the following calculation:

Tightening torque: 3.5 N·m (0.4 kgf-m, 2.6 ft-lb) NOTE: • Clean the battery cable terminals and apply grease to retard the formation of corrosion. • Connect the battery positive (+) terminal, and then connect the negative (–) terminal. • After the battery is installed, initial diagnosis of the electronic throttle control is performed. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine.

C: INSPECTION WARNING: • Electrolyte is corrosive acid, and has toxicity; be careful of handling the fluid. • Make sure the electrode does not come into contact with skin, eyes or clothing. Especially at contact with eyes, flush with water for 15 minutes and get prompt medical attention. • In addition, be careful not to let the electrode contact with the coated parts. • Be careful when handling the batteries because they produce explosive gases. • Be sure to keep battery away from any fire. • For safety, in case an explosion does occur, wear eye protection or shield your eyes when working near any battery. In addition, never lean over the battery.

S20 = St + 0.0007 × (t – 20) S20: Specific gravity corrected at electrolyte temperature of 20°C (68°F) St: Measured specific gravity t: Measured temperature (°C) Judge whether or not battery must be charged, according to corrected specific gravity. Standard specific gravity: 1.220 — 1.290 [at 20°C (68°F)] 2) Measuring the specific gravity of the electrolyte in the battery will disclose the state of charge of the battery. The relation between specific gravity and state of charge is as shown in the figure.

SC(H4SO)-26

Specific gravity [20˚C (68˚F)]

Install in the reverse order of removal.

1.28 1.26 1.24 1.22 1.20 1.18 1.16 1.14 1.12 100%

75% 50%

22%

0%

Complete charge Charging condition (%) Specific gravity and state of charge SC-00094

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Battery STARTING/CHARGING SYSTEMS

D: MEASUREMENT WARNING: Do not bring an open flame close to the battery when working.

CAUTION: • Observe the items in 3. NORMAL CHARGING. • Never use 10 A or more when charging the battery because it will shorten the battery life.

CAUTION: • Prior to charging, corroded terminals should be cleaned with a brush and common caustic soda solution. • Be careful since battery electrolyte overflows while charging the battery. • Observe instructions when handling the battery charger. • Before charging the battery on the vehicle, disconnect the battery ground terminal to prevent damage of generator diodes or other electrical units.

1. JUDGMENT OF BATTERY IN CHARGED CONDITION 1) Specific gravity of electrolyte should be held within the specific range from 1.250 to 1.290 for one hour or more. 2) Voltage per battery cell should be held at a specific value in a range from 2.5 to 2.8 V for one hour or more.

2. CHECK CONDITION OF CHARGE WITH HYDROMETER Hydrometer indicator

State of charge

Corrective action

Green dot Dark dot

65% or more 65% or less

Load test Charge battery

Low electroReplace the battery.* lyte (If cranking is difficult) * Check electrical system before replacement. Clear dot

3. NORMAL CHARGING Charge the battery at the current value specified by manufacturer or at approximately 1/10 of battery’s ampere-hour rating.

4. QUICK CHARGING Quick charging is a method that the battery is charged in a short period of time with a relatively large current by using a quick charger. Since a large current flow raises electrolyte temperature, the battery is subject to damage if the large current is used for prolonged time. For this reason, the quick charging must be carried out within a current range that will not increase the electrolyte temperature above 40°C (104°F). Also the quick charging is a temporary mean to bring battery voltage up to some level, and battery should be charged slowly with low current as a rule.

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Battery STARTING/CHARGING SYSTEMS

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ENGINE (DIAGNOSTICS)

EN(H4SO)(diag) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Page Basic Diagnostic Procedure .......................................................................2 Check List for Interview ..............................................................................4 General Description ...................................................................................6 Electrical Component Location ..................................................................9 Engine Control Module (ECM) I/O Signal ................................................18 Engine Condition Data .............................................................................28 Data Link Connector ................................................................................29 General Scan Tool ...................................................................................30 Subaru Select Monitor ..............................................................................34 Read Diagnostic Trouble Code (DTC) .....................................................41 Inspection Mode .......................................................................................42 Drive Cycle ...............................................................................................47 Clear Memory Mode .................................................................................54 System Operation Check Mode ...............................................................55 Malfunction Indicator Light .......................................................................56 Diagnostics for Engine Starting Failure ....................................................66 List of Diagnostic Trouble Code (DTC) ....................................................79 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................86 General Diagnostic Table .......................................................................300

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Basic Diagnostic Procedure ENGINE (DIAGNOSTICS)

1. Basic Diagnostic Procedure A: PROCEDURE 1. ENGINE 1

Step Check CHECK ENGINE START FAILURE. Does the engine start? 1) Ask the customer when and how the trouble occurred using the interview check list. 2) Start the engine.

2

CHECK ILLUMINATION OF MALFUNCTION Does the malfunction indicator light illuminate? INDICATOR LIGHT.

3

CHECK COMMUNICATION STATUS. Does Subaru select monitor or 1) Turn the ignition switch to OFF. general scan tool communicate 2) Connect the Subaru Select Monitor or gen- with vehicle normally? eral scan tool to data link connector. 3) Turn the ignition switch to ON, and run the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed procedures, refer to “Subaru Select Monitor”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

4

CHECK DTC. Is DTC displayed on Subaru Read DTC using Subaru Select Monitor or gen- Select Monitor or general scan eral scan tool. tool? NOTE: • Subaru Select Monitor Refer to “Read Diagnostic Trouble Code” for detailed operation procedure. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H4SO)(diag)-2

Yes Go to step 2.

No Inspection using “Diagnostics for Engine Start Failure”. Go to step 3. Inspection using “General Diagnostic Table”. Go to step 4. Inspection using LAN system “Diagnostic Procedure with Diagnostic Trouble Code (DTC)”. Record the DTC. Repair the related Repair the trouble parts. cause. function indicator Go to step 5. light illuminates, perform the diagnosis of malfunction indicator light circuit or combination meter.

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Basic Diagnostic Procedure ENGINE (DIAGNOSTICS)

5

6

Step CHECK FREEZE FRAME DATA. Check the freeze frame data using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed procedures, refer to “Subaru Select Monitor”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. PERFORM DIAGNOSIS. 1) Perform the Clear Memory Mode. 2) Perform the Inspection Mode or drive cycle.

Check Yes No Is freeze frame data displayed Record the freeze Go to step 6. on Subaru Select Monitor or frame data. Repair general scan tool? the cause of fault, and go to the next step. Go to step 6.

Inspect using Is DTC displayed on Subaru Finish the diagnoSelect Monitor or general scan “Diagnostic Proce- sis. dure with Diagnostool? tic Trouble Code (DTC)”.

EN(H4SO)(diag)-3

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Check List for Interview ENGINE (DIAGNOSTICS)

2. Check List for Interview A: CHECK 1. CHECK LIST NO. 1 Check the following item when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer’s name Date of purchase Date of repair V.I.N. Weather

Engine No. Fuel brand

Fine Cloudy Rainy Snowy Various/Others:

Ambient air temperature

Place

Engine temperature

Engine speed Vehicle speed Driving conditions

Headlight Blower A/C compressor Radiator fan Front wiper Rear wiper

km miles

Odometer reading

°C (

°F)

Hot Warm Cool Cold Highway Suburbs Inner city Uphill Downhill Rough road Others: Cold Warming-up After warming-up Any temperature Others: rpm km/h (MPH) Not affected At starting While idling At racing While accelerating While cruising While decelerating While turning (RH/LH) ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF

Rear defogger Audio CD/Cassette Car phone Wireless device

EN(H4SO)(diag)-4

ON/ ON/ ON/ ON/ ON/

OFF OFF OFF OFF OFF

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Check List for Interview ENGINE (DIAGNOSTICS)

2. CHECK LIST NO. 2 Check the following item about the vehicle’s state when malfunction indicator light turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators illuminate. Yes / No Low fuel warning light Charge indicator light Engine coolant temperature warning light Oil pressure warning light ATF temperature warning light or SPORT indicator light Driver’s control center differential indicator light ABS warning light VDC warning light Cruise indicator light SI-CRUISE warning light Immobilizer indicator light STEERING warning light Electronic parking brake warning light Glow indicator light Sedimentor warning light Others: b) Fuel level • Lack of fuel: Yes / No • Indicator position of fuel gauge: • Experienced running out of fuel: Yes / No c) Intentional connecting or disconnecting of harness connectors or spark plug cords: Yes / • What: d) Intentional connecting or disconnecting of hoses: Yes / No • What: e) Installing of other parts except genuine parts: Yes / No • What: • Where: f) Occurrence of noise: Yes / No • From where: • What kind: g) Occurrence of smell: Yes / No • From where: • What kind: h) Intrusion of water into engine compartment or passenger compartment: Yes / No i) Troubles occurred Engine does not start. Engine stalls during idling. Engine stalls while driving. Engine speed decreases. Engine speed does not decrease. Rough idling Poor acceleration Back fire After fire Does not shift. Excessive shift shock

EN(H4SO)(diag)-5

No

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General Description ENGINE (DIAGNOSTICS)

3. General Description

7) Use ECM mounting stud bolts at the body side grounding point when measuring voltage and resistance inside the passenger compartment.

A: CAUTION 1) Airbag system wiring harness is routed near the ECM, main relay and fuel pump relay. CAUTION: • Do not use electrical test equipment on the airbag system circuit. • Be careful not to damage the airbag system wiring harness when servicing the ECM, TCM, main relay and fuel pump relay. 2) Never connect the battery in reverse polarity. Doing so will damage the ECM instantly, and other parts will also be damaged. 3) Do not disconnect the battery terminals while the engine is running. A large counter electromotive force will be generated in the generator, and this voltage may damage electronic parts such as ECM etc. 4) Before disconnecting the connectors of each sensor and ECM, be sure to turn the ignition switch to OFF. Perform the Clear Memory Mode after connecting the connectors. 5) When measuring the voltage or resistance of individual sensor or all electrical control modules, use a tapered pin with a diameter of less than 0.6 mm (0.024 in). Do not insert the pin 4 mm (0.16 in) or more into the part. CAUTION: When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system. NOTE: When replacing the ECM of the models with Immobilizer, immobilizer system must be registered. To do so, all ignition keys and ID cards need to be prepared. Refer to the “PC application help for Subaru Select Monitor”. 6) Take care not to allow water to get into the connectors when servicing or washing the vehicle in rainy weather. Avoid exposure to water even if the connectors are waterproof.

(A)

EN-07713

(A) Stud bolt

8) Use the engine ground terminal or engine assembly for the grounding point to chassis when measuring the voltage and resistance in engine compartment.

EN-07710

9) Every MFI-related part is a precision part. Do not drop them. 10) Observe the following cautions when installing a radio in vehicle. CAUTION: • The antenna must be kept as far apart as possible from control module. (ECM is installed at the back of the glove box.) • The antenna feeder must be placed as far apart as possible from the ECM and engine control system harness. • Carefully adjust the antenna for correct matching. • When mounting a large power type radio, pay special attention to the three items mentioned above. • Incorrect installation of the radio may affect the operation of ECM. 11) When disconnecting the fuel hose, release the fuel pressure.

EN(H4SO)(diag)-6

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General Description ENGINE (DIAGNOSTICS)

12) For the model with ABS, the ABS warning light may illuminate when performing driving test with jacked-up or lifted-up condition, but this is not a system malfunction. The reason for this is the speed difference between the front and rear wheels. When engine control system diagnosis is finished, perform the VDC memory clearance procedure of self-diagnosis function.

B: INSPECTION Before performing diagnostics, check the following item which might affect engine problems.

1. BATTERY 1) Measure the battery voltage and specific gravity of the electrolyte.

Standard voltage: 12 V Specific gravity: 1.260 or more 2) Check the condition of the main and other fuses, and harnesses and connectors. Also check for proper grounding.

• When the system decides that a malfunction occurs, malfunction indicator light illuminates. At the same time of the malfunction indicator light illumination or blinking, a DTC and a freeze frame engine conditions are stored into on-board computer. • The OBD system stores freeze frame engine condition data (engine load, engine coolant temperature, fuel trim, engine speed and vehicle speed, etc.) into on-board computer when it detects a malfunction. • Freeze frame engine condition data are stored until the DTCs are cleared. However when such malfunctions as fuel trim fault and misfire are detected with the freeze frame engine condition data stored, they are rewritten into those related to the fuel trim fault and misfire. • When the malfunction does not occur again for three consecutive driving cycles, malfunction indicator light is turned off, but DTC remains at onboard computer. • When performing diagnosis, connect the Subaru Select Monitor or general scan tool to the vehicle.

2. ENGINE GROUND Make sure that the engine ground terminal has no contamination, corrosion or looseness and is properly connected to the engine.

EN-07710

C: NOTE • The on-board diagnostic (OBD) system detects and indicates a fault in various inputs and outputs of the complex electronic control. Malfunction indicator light in the combination meter indicates occurrence of a fault or trouble. • Further, against such a failure of sensors as may disable the drive, the fail-safe function is provided to ensure the minimal driveability. • The OBD system incorporated with the vehicles within this type of engine complies with OBD-II regulations. The OBD system monitors the components and the system malfunction listed in “Engine Section” which affects on emissions.

EN(H4SO)(diag)-7

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General Description ENGINE (DIAGNOSTICS)

D: PREPARATION TOOL ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

1B022XU0

SUBARU SELECT MONITOR III KIT

Used for troubleshooting the electrical system.

499987500

CRANKSHAFT SOCKET

Used for rotating crankshaft.

ST1B022XU0

ST-499987500

EN(H4SO)(diag)-8

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Electrical Component Location ENGINE (DIAGNOSTICS)

4. Electrical Component Location A: LOCATION 1. CONTROL MODULE (1)

(3)

(2)

(4) EN-07690

(1) (2)

Engine control module (ECM) Malfunction indicator light

(3)

Delivery (test) mode fuse

(4)

Data link connector

(1) CHECK ENGINE

CHECK ENGINE

(2)

EN-07715

EN-07716

(3)

(4) EN-07511

EN(H4SO)(diag)-9

EN-07717

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Electrical Component Location ENGINE (DIAGNOSTICS)

2. SENSOR (3)

(1)

(4)

(8)

(2)

(7)

(5)

(6) EN-07691

(1) (2) (3)

Mass air flow and intake air temperature sensor Manifold absolute pressure sensor Engine coolant temperature sensor

(4)

Electronic throttle control

(7)

Crankshaft position sensor

(5) (6)

Knock sensor Camshaft position sensor

(8)

Oil temperature sensor

EN(H4SO)(diag)-10

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Electrical Component Location ENGINE (DIAGNOSTICS)

(2) (1)

EN-07595

EN-07596

(3) (4) EN-07597

EN-07598

(6)

(5) EN-07599

EN-07600

(7) (8)

EN-07601

EN(H4SO)(diag)-11

EN-07602

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Electrical Component Location ENGINE (DIAGNOSTICS)

(4)

(2)

(3) (1)

EN-07603

(1) (2)

Front oxygen (A/F) sensor Rear oxygen sensor

(3)

Front catalytic converter

(4)

(1) (2)

Rear catalytic converter

(3)

(4) EN-07692

(1) (2)

Fuel level sensor Fuel temperature sensor

(3)

Fuel tank pressure sensor

EN(H4SO)(diag)-12

(4)

Fuel sub level sensor

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Electrical Component Location ENGINE (DIAGNOSTICS)

(3)

(1)

(2) EN-07718

(4)

EN-07720

EN(H4SO)(diag)-13

EN-07719

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Electrical Component Location ENGINE (DIAGNOSTICS)

3. SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS (3)

(4)

(2)

(1)

(4)

(3) EN-07693

(1)

Purge control solenoid valve

(2)

EGR valve

(3)

Oil switching solenoid valve

(4)

Variable valve lift diagnosis oil pressure switch

(3) (1)

(2)

EN-07605

EN(H4SO)(diag)-14

EN-07606

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Electrical Component Location ENGINE (DIAGNOSTICS)

(4) (3) EN-07707

EN(H4SO)(diag)-15

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Electrical Component Location ENGINE (DIAGNOSTICS) (3) (4) (5) (6) (7)

(8) (9) (10)

(1) (2) (3) (4) (5)

Starter Fuel pump Main relay IG relay A/F, oxygen sensor relay

(1)

(2)

(11)

(6) (7) (8) (9) (10)

(13)

Electronic throttle control relay Fuel pump relay Radiator main fan relay 1 Radiator main fan relay 2 Radiator sub fan relay

EN(H4SO)(diag)-16

(11) (12) (13) (14)

(12)

(14)

Starter relay Canister Drain valve Drain filter

EN-07694

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Electrical Component Location ENGINE (DIAGNOSTICS)

(2)

(1) EN-07512

EN-07752

(3) (4) (5) (9)

(6)

(8)

(7)

(10) EN-07721

EN-07514

(14)

(13)

(12) (11) EN-07722

EN-07723

4. TRANSMISSION

(2)

(1) EN-07518

(1)

Inhibitor switch (CVT model)

(2)

Neutral position switch (MT model)

EN(H4SO)(diag)-17

EN-07724

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION

TO A:

B134

7 6 5 4 3 17 16 15 14 13 12 11 27 26 25 24 23 22 21 34 33 32 31

B135

TO B: 2 1 10 9 8 20 19 18 30 29 28

TO C:

7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 35 34 33 32 31 30 29 28

B136

TO D:

6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 27 26 25 24 23 22 21 20 19 18 17 30 29 28 35 34 33 32 31

B137

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26

EN-05288

Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 0 –7 — +7 0 0 0 0 0 –7 — +7 0 0 0 0 0.64 — 0.72 0.64 — 0.72 Fully open: Approx. (After engine is 4.04 warmed up.) 1.51 — 1.58 1.51 — 1.58 Fully open: Approx. (After engine is 4.232 warmed up.)

Description

Connector No.

Terminal No.

Signal (+) Crankshaft position sen- Signal (–) sor Shield Signal (+) Camshaft position sen- Signal (–) sor Shield

B137 B137 B137 B137 B137 B137

17 25 31 24 30 31

Main

B134

18

Sub

B134

28

Power supply

B134

19

5

5



Ground (sensor)

B134

29

0

0



Electronic throttle control motor (+)

B134

2

Duty waveform

Duty waveform

Drive frequency: 500 Hz

Electronic throttle control motor (–)

B134

1

Duty waveform

Duty waveform

Drive frequency: 500 Hz

B135

7

10 — 13

12 — 14



B135

17

ON: 0 OFF: 10 — 13

ON: 0 OFF: 12 — 14

When ignition switch is turned to ON: ON

Electronic throttle control

Electronic throttle control motor power supply Electronic throttle control motor relay

EN(H4SO)(diag)-18

Note Waveform — — Waveform — — Fully closed: Approx. 0.6 Fully open: Approx. 4.04 Fully closed: Approx. 1.48 Fully open: Approx. 4.232

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Terminal No.

B135

23

B135

21

5

5



B135

29

0

0



B135

31

Fully closed: 1.0 Fully opened: 3.5

Fully closed: 1.0 Fully opened: 3.5



Sub power supply

B135

22

5

5



GND (Sub sensor)

B135

30

0

0



Signal Shield

B136 B136

20 9

0 0

0 — 0.9 0

— —

B136

6

10 — 13

1 — 14

Duty waveform

B136

5

10 — 13

1 — 14

Duty waveform

B135

6

10 — 13

1 — 14

Duty waveform

B137

22

1.0 — 1.4

1.0 — 1.4

After engine is warmed up.

Main sensor signal

Accelerator pedal position sensor

Rear oxygen sensor

Signal (V) Engine ON Ignition SW ON (engine OFF) (idling) Fully closed: 1.0 Fully closed: 1.0 Fully opened: 3.5 Fully opened: 3.5

Connector No.

Description

Main power supply GND (Main sensor) Sub sensor signal

Front oxygen Signal 1 (A/F) sensor Signal 2 heater Rear oxygen sensor heater signal Engine coolant temperature sensor

Note —

Starter switch

B136

16

0

0

CVT model Cranking: 8 — 14 MT model Cranking with the clutch pedal pressed: 8 — 14

Starter relay control

B135

26

ON: 0.5 or less OFF: 10 — 13

ON: 0.5 or less OFF: 12 — 14



Ignition switch

B136

30

10 — 13

12 — 14

Neutral position switch

B136

35

Delivery (test) mode fuse

B136

34

10 — 13

13 — 14

— CVT model: Switch is ON when select lever is in “P” range or “N” range. MT model: Switch is ON when shift lever is in neutral. When fuse is installed: 0

B137 B137

2 8

2.5 0

2.5 0

— —

Back-up power supply

B136

2

10 — 13

12 — 14

Ignition switch “OFF”: 10 — 13

Control module power supply

B137 B136

7 1

10 — 13 10 — 13

12 — 14 12 — 14

— —

B134 B134 B134 B134 B134 B134 B134 B134

21 22 31 32 10 11 12 13

0 0 0 0 10 — 13 10 — 13 10 — 13 10 — 13

0 or 5 0 or 5 0 or 5 0 or 5 1 — 14 1 — 14 1 — 14 1 — 14

Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform

Knock sensor

Ignition control

Fuel injector

Signal Shield

#1 #2 #3 #4 #1 #2 #3 #4

ON: 0 OFF: 12±0.5

EN(H4SO)(diag)-19

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Ignition SW ON Engine ON (engine OFF) (idling)

Connector No.

Terminal No.

Fuel pump relay control

B136

33

ON: 0.5 or less OFF: 10 — 13

ON: 0.5 or less OFF: 12 — 14



Radiator fan relay 1 control

B135

12

ON: 0.5 or less OFF: 10 — 13

ON: 0.5 or less OFF: 12 — 14



Radiator fan relay 2 control

B135

11

ON: 0.5 or less OFF: 10 — 13

ON: 0.5 or less OFF: 12 — 14



Self-shutoff control

B135

13

0.5 or less

0.5 or less

Malfunction indicator light

B135

33





Engine speed output Oil temperature sensor signal

B135

15



0 — 13 or more

— Light “ON”: 1 or less Light “OFF”: 10 — 14 Waveform

B137

21

1.0 — 1.4

1.0 — 1.4

After engine is warmed up.

B137

6

ON: 1 or less OFF: 10 — 13

ON: 1 or less OFF: 12 — 14

Duty waveform

B134 B134 B134 B134

8 9 20 30

0 or 10 — 13 0 or 10 — 13 0 or 10 — 13 0 or 10 — 13

0 or 12 — 14 0 or 12 — 14 0 or 12 — 14 0 or 12 — 14

Waveform Waveform Waveform Waveform

B137

28

ON: 1 or less OFF: 10 — 13

ON: 1 or less OFF: 12 — 14



Blower motor relay

B135

19

ON: 0 OFF: 10 — 13

ON: 0 OFF: 12 — 14

Manual A/C

Oil level switch Signal (+) Oil switching solenoid Signal (–) valve RH Oil switchSignal (+) ing solenoid Signal (–) valve LH Variable valve lift diagnosis oil pressure switch RH

B136 B134

26 7

0 0

0 Duty waveform

Oil level LOW: 10 — 14 Drive frequency: 300 Hz

B134

15

0

0



B134

5

0

Duty waveform

Drive frequency: 300 Hz

B134

14

0

0



B137

14

0

0



Variable valve lift diagnosis oil pressure switch LH

B137

13

0

0



B136 B136 B136

19 18 9

— — 0

2.7 — 2.9 2.35 — 2.25 0

— — —

B137

20

3.4 — 3.8

1.4 — 1.8



B136 B136 B136

22 10 11

— 0 0

0.3 — 4.5 0 0

— — —

B136

31

0.3 — 4.6

0.3 — 4.6



Immobilizer communication

B135

25

1 or less ←→ 4 or more

SSM communication line

B135

14

Sensor power supply

B134 B135

19 22

1 or less ←→ 4 or more 1 or less ←→ 4 or more 5 5

Description

Purge control solenoid valve Signal 1 Signal 2 EGR valve Signal 3 Signal 4 Power steering oil pressure switch

Signal (+) Signal (–) Shield Manifold absolute pressure sensor Front oxygen (A/F) sensor

Signal Shield Ground Intake air temperature sensor signal Air flow sensor

1 or less ←→ 4 or more 5 5

EN(H4SO)(diag)-20

Note

— — — —

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

Description

Sensor

Ground

Engine 1 Engine 2 Engine 3 Engine 4 Engine 5 Body

Clutch switch

Brake switch 1 (brake switch)

Connector No.

Terminal No.

B134 B135 B134 B134 B134 B137 B137 B136

29 30 6 4 3 1 3 4

B135

9

B136

Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 When clutch pedal is When clutch pedal is depressed: 0 depressed: 0 When clutch pedal is When clutch pedal is released: 10 — 13 released: 12 — 14

Note — — — — — — — — —

15

When brake pedal is depressed: 0 When brake pedal is released: 10 — 13

When brake pedal is depressed: 0 When brake pedal is released: 12 — 14



When brake pedal is depressed: 12 — 14 When brake pedal is released: 0



ON: 0 OFF: 5



Brake switch 2 (stop light switch)

B136

3

When brake pedal is depressed: 10 — 13 When brake pedal is released: 0

Cruise control main switch

B136

13

ON: 0 OFF: 5

When operating When operating nothing: 3.5 — 4.5 nothing: 3.5 — 4.5 When operating When operating RES/ACC: 2.5 — 3.5 RES/ACC: 2.5 — 3.5 When operating SET/ When operating SET/ COAST: 0.5 — 1.5 COAST: 0.5 — 1.5 When operating When operating CANCEL: 0 — 0.5 CANCEL: 0 — 0.5

Cruise control command switch

B136

12

Fuel temperature sensor

B136

23

2.5 — 3.8

2.5 — 3.8

Fuel tank pressure sensor

B136

21

2.3 — 2.7

2.3 — 2.7

Drain valve

B135

4

ON: 1 or less OFF: 10 — 13

ON: 1 or less OFF: 12 — 14



B136 B136

17 28

2.5 — 3.5 1.5 — 2.5

2.5 — 3.5 1.5 — 2.5

Waveform Waveform

CAN communication

(Hi) (Lo)

EN(H4SO)(diag)-21



Outside temperature: 25°C (77°F) Value after removing fuel filler cap and installing again

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

Input/output name: • Crankshaft position sensor • Camshaft position sensor Measuring condition: • After warming-up • At idling

CRANKSHAFT POSITION SENSOR

0

ONE CRANKSHAFT ROTATION

CAMSHAFT POSITION SENSOR

0 10 ms 5V

ONE CAMSHAFT ROTATION

EN-07430

EN(H4SO)(diag)-22

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

F/B FUSE No. 4 DATA LINK CONNECTOR

STARTER MOTOR

MT

CVT

M/B FUSE No. 12

C2 B9 P R N D

INHIBITOR SWITCH MT

CVT

NEUTRAL POSITION SWITCH MT

CLUTCH SWITCH B14

1 C34

MT C35

IGNITION SWITCH F/B FUSE No. 21

DELIVERY (TEST) MODE FUSE

B26

MT

MT

CVT STARTER RELAY

MT

C16

C4

1

CLUTCH STROKE SENSOR C30

F/B FUSE No. 12

MT

B23

ACCELERATOR PEDAL POSITION SENSOR

M/B FUSE No. 20 B21 B31

FUEL PUMP RELAY C33

B29

B22 FUEL PUMP POWER STEERING OIL PRESSURE SWITCH D28

C21

FUEL TANK PRESSURE SENSOR

B30

3

2

EN-07695

EN(H4SO)(diag)-23

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

M/B FUSE No. 16 M/B FUSE No. 13 M/B FUSE No. 15 M/B FUSE No. 14

A/F, OXYGEN SENSOR RELAY

MAIN RELAY

IG RELAY

A21

IGNITION COIL No. 1

A22

IGNITION COIL No. 2

A31

IGNITION COIL No. 3

A32

IGNITION COIL No. 4

B13 ELECTRONIC THROTTLE CONTROL RELAY

4 B7 B17

C1

9

D7

PURGE CONTROL SOLENOID VALVE

D6 F/B FUSE No. 7 F/B FUSE No. 5

A8 B33

A9

EGR VALVE

A20

BODY INTEGRATED UNIT (CAN COMMUNICATION)

COMBINATION METER

B15

5 A30

EN-07696

EN(H4SO)(diag)-24

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

5

2

FUEL INJECTOR No. 1

A10

A18

A28 FUEL INJECTOR No. 2

A11 ELECTRONIC THROTTLE CONTROL A1 A2 A19

FUEL INJECTOR No. 3

6

A12

MANIFOLD ABSOLUTE PRESSURE SENSOR

D20 A29

FUEL INJECTOR No. 4

A13 D22 ENGINE COOLANT TEMPERATURE SENSOR

7 DRAIN VALVE

OIL TEMPERATURE SENSOR

B4 D21

3 5

C23

FUEL TEMPERATURE SENSOR

EN-07697

EN(H4SO)(diag)-25

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

3 MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

5

C31 C11 D13

VVL DIAGNOSIS OIL PRESSURE SWITCH LH

D14

VVL DIAGNOSIS OIL PRESSURE SWITCH RH

C22

4 C10

A5 OIL SWITCHING SOLENOID VALVE LH

A14

C18 FRONT OXYGEN (A/F) SENSOR RH

C19

A7 OIL SWITCHING SOLENOID VALVE RH

A15

C5

7

C6

D17

C9

D25

CRANKSHAFT POSITION SENSOR

B6 REAR OXYGEN SENSOR LH C20

D24 CAMSHAFT POSITION SENSOR

D30

8

D31

10 7 KNOCK SENSOR

D2

D8

6

EN-07698

EN(H4SO)(diag)-26

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

STOP LIGHT SWITCH

C3 C26

BRAKE SWITCH

OIL LEVEL SWITCH

C15

B19

BLOWER MOTOR RELAY

C12

CRUISE CONTROL SWITCH C13

10 6 BODY INTEGRATED UNIT (IMMOBILIZER)

B25

9

8

D1 A3 A4

C17 BODY INTEGRATED UNIT (CAN COMMUNICATION)

SUB FAN RELAY

MAIN FAN RELAY

A6 D3

C28

B11

B12

ENGINE GROUND

EN-07699

EN(H4SO)(diag)-27

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Engine Condition Data ENGINE (DIAGNOSTICS)

6. Engine Condition Data A: ELECTRICAL SPECIFICATION Contents Engine load

Specification 17.6 — 40.5 (%): Idling 14.7 — 29.8 (%): 2,500 rpm racing

Measuring condition: • After engine is warmed up. • Set the select lever in “P” range or “N” range, or the shift lever in neutral. • Turn the A/C to OFF. • Turn all the accessory switches to OFF.

EN(H4SO)(diag)-28

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Data Link Connector ENGINE (DIAGNOSTICS)

7. Data Link Connector A: NOTE This connector is used for Subaru Select Monitor. CAUTION: Do not connect any scan tools other than Subaru Select Monitor or general scan tool because the circuit for Subaru Select Monitor may be damaged.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

EN-07824

Terminal No. 1 2 3 4 5 6 7 8

Contents Empty Empty Empty Ground Ground CAN communication (Hi) Subaru Select Monitor signal Empty

Terminal No. 9 10 11 12 13 14 15 16

EN(H4SO)(diag)-29

Contents Empty Empty Empty Empty Empty CAN communication (Lo) Empty Power supply

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General Scan Tool ENGINE (DIAGNOSTICS)

8. General Scan Tool A: OPERATION 1. HOW TO USE GENERAL SCAN TOOL 1) Prepare a scan tool (general scan tool) required by SAE J1978. 2) Connect the general scan tool to the data link connector located in the lower portion of the instrument panel (on the driver’s side).

EN-07712

3) Using the general scan tool, call up each data. General scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic data (2) MODE $02: Powertrain freeze frame data (3) MODE $03: Emission-related powertrain DTC (4) MODE $04: Clear/Reset emission-related diagnostic information (5) MODE $06: Request on-board monitoring test results for intermittently monitored systems (6) MODE $07: Request on-board monitoring test results for continuously monitored systems (7) MODE $09: Request vehicle information Read out the data according to repair procedures. (For detailed operation procedure, refer to the general scan tool operation manual.) NOTE: For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”.

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General Scan Tool ENGINE (DIAGNOSTICS)

2. MODE $01: (CURRENT POWERTRAIN DIAGNOSTIC DATA) Refer to data denoting the current operating condition of analog input/output, digital input/output or the powertrain system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. PID $01 $03 $04 $05 $06 $07 $0B $0C $0D $0E $0F $10 $11 $13 $15 $1C $1F $21 $24 $2C $2D $2E $2F $30 $31 $32 $33 $34 $3C $41 $42 $43 $44 $45 $46 $47 $49 $4A $4C $4D $4E $51 $5A $65

Data Number of emission-related powertrain DTC, and malfunction indicator light status and diagnosis support information Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim Long term fuel trim Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance Intake air temperature Intake air amount Throttle valve opening angle Air fuel ratio sensor Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (Bank 1 Sensor 2) Supporting OBD system Elapsed time after starting the engine Driving distance after the malfunction indicator light illuminates A/F value and A/F sensor output voltage (Bank 1 Sensor 1) Target EGR EGR deviation Evaporative purge Fuel level Number of warm ups after DTC clear Driving distance after DTC clear Fuel tank pressure Atmospheric pressure A/F value and A/F sensor current (Bank 1 Sensor 1) Catalytic temperature #1 Diagnosis monitoring per drive cycle ECM power voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute acceleration opening angle 1 Absolute acceleration opening angle 2 Target throttle opening angle Engine operating time while malfunction indicator light is illuminating Elapsed time after DTC clear Fuel used Relative acceleration opening angle Neutral status

Unit of measure — — % °C % % kPa rpm MPH ° °C g/s % — V and % — sec miles – and V % % % % — miles Pa kPa – and mA °C — V % — % °C % % % % min min — % —

NOTE: Refer to general scan tool manufacturer’s instruction manual to access generic OBD-II PIDs (MODE $01).

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General Scan Tool ENGINE (DIAGNOSTICS)

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) Refer to data denoting the operating condition when trouble is sensed by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. PID $02 $03 $04 $05 $06 $07 $0B $0C $0D $0E $0F $10 $11 $13 $15 $1C $1F $2C $2D $2E $2F $32 $33 $42 $43 $44 $45 $46 $47 $49 $4A $4C $65

Data DTC that caused the freeze frame data storage required by CARB Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim (Bank 1 Sensor 1) Long term fuel trim (Bank 1 Sensor 1) Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance Intake air temperature Intake air amount Throttle valve opening angle Air fuel ratio sensor Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (Bank 1 Sensor 2) Supporting OBD system Elapsed time after starting the engine Target EGR EGR deviation Evaporative purge Fuel level Fuel tank pressure Atmospheric pressure ECM power voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute acceleration opening angle 1 Absolute acceleration opening angle 2 Target throttle opening angle Neutral status

Unit of measure — — % °C % % kPa rpm MPH ° °C g/s % — V and % — sec % % % % Pa kPa V % — % °C % % % % —

NOTE: Refer to general scan tool manufacturer’s instruction manual to access freeze frame data (MODE $02).

4. MODE $03 (EMISSION-RELATED POWERTRAIN DTC) Refer to “List of Diagnostic Trouble Code (DTC)” for information about data denoting emission-related powertrain DTC.

5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION) Refer to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic information). NOTE: • Refer to general scan tool manufacturer’s instruction manual to clear the emission-related diagnostic information (MODE $04). • Initial diagnosis of electronic throttle control is performed after memory clearance. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine.

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General Scan Tool ENGINE (DIAGNOSTICS)

6. MODE $06 Refer to test value of troubleshooting and data of test limit indicated on the support data bit sequence table. A list of the support data is shown in the following table. OBDMID

TID $81 $82 $83 $84 $85 $86 $87 $88 $07 $08 $A5 $05 $06 $89 $8A $93 $94 $95 $A6

SID $0A $8D $14 $1E $1E $20 $0B $0B $0B $0B $0B $10 $10 $20 $FD $FE $FE $FE $FE

$96 $97 $98 $99 $9A $9B

$FE $FE $FE $24 $24 $14

$42

$9C $9D

$24 $24

Oxygen sensor heater failure (Bank 1 Sensor 2)

$A1

$0B $0C

$24 $24

Misfire monitoring (All cylinders)

$A2

$0B $0C

$24 $24

Misfire monitoring (#1 cylinder)

$A3

$0B $0C

$24 $24

Misfire monitoring (#2 cylinder)

$A4

$0B $0C

$24 $24

Misfire monitoring (#3 cylinder)

$A5

$0B $0C

$24 $24

Misfire monitoring (#4 cylinder)

$01

$02

$21 $31 $39 $3B

$3C $3D $41

Diagnostic item A/F sensor continuity failure (Bank 1 Sensor 1)

A/F sensor range failure (Bank 1 Sensor 1) A/F sensor response failure (Bank 1 Sensor 1) Oxygen sensor circuit failure (Bank 1 Sensor 2)

Oxygen sensor drop failure (Bank 1 Sensor 2)

Oxygen sensor response failure (Bank 1 Sensor 2) Catalyst deterioration diagnosis (Bank 1) EGR system diagnosis Evaporative emission control system (Cap off) Evaporative emission control system (0.04 inch leak)

Evaporative emission control system (0.02 inch leak) Evaporative emission control system (Purge flow) A/F sensor heater failure (Bank 1 Sensor 1) A/F sensor heater characteristics failure (Bank 1 Sensor 1)

7. MODE $07 Refer to the data of DTC (pending code) for troubleshooting result about emission in the first time.

8. MODE $09 Refer to data of vehicle specification (V.I.N., calibration ID, diagnosis frequency etc.).

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Subaru Select Monitor ENGINE (DIAGNOSTICS)

9. Subaru Select Monitor A: OPERATION 1. HOW TO USE THE SUBARU SELECT MONITOR NOTE: For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

2. READ CURRENT DATA FOR ENGINE (NORMAL MODE) NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • A list of the support data is shown in the following table. Contents Engine load

Display Engine Load

Unit of measure %

Engine coolant temperature signal

Coolant Temp.

A/F correction #1 A/F learning #1

A/F Correction #1 A/F Learning #1

Intake manifold absolute pressure

Mani. Absolute Pressure

Engine speed signal

Engine Speed

rpm

Meter vehicle speed signal

Vehicle Speed

km/h or MPH

Ignition timing signal Intake air temperature signal Intake air amount Throttle opening angle signal Rear oxygen sensor voltage Battery voltage Mass air flow voltage

Ignition Timing Intake Air Temp. Mass Air Flow Throttle Opening Angle Rear O2 Sensor Battery Voltage Air Flow Sensor Voltage

Injection 1 pulse width

°C or °F % % mmHg, kPa, inHg or psig

Note (at idling) 21.0% 85°C or 185°F or more (after warm-up) –0.8% 0.0% 200 — 300 mmHg, 26.7 — 40 kPa, 7.8 — 11.8 inHg or 3.8 — 5.8 psig 700 rpm (Agree with the tachometer indication)

deg °C or °F g/s or lb/m % V V V

0 km/h or 0 MPH (at parking) 14 — 16 deg (Ambient air temperature) 2.5 g/s or 0.33 lb/m 2.0% 0.1 — 0.7 V 12 — 14 V 1.26 V

Fuel Injection #1 Pulse

ms

2.82 ms

Atmospheric pressure signal

Atmosphere Pressure

mmHg, kPa, inHg or psig

(Atmospheric pressure)

Intake manifold relative pressure

Mani. Relative Pressure

mmHg, kPa, inHg or psig

Learned ignition timing Acceleration opening angle signal Fuel temperature signal Purge control solenoid duty ratio Number of EGR steps A/F sensor current value 1

Learned Ignition Timing Accel. Opening Angle Fuel Temp. CPC Valve Duty Ratio No. of EGR steps A/F Sensor #1 Current

deg % °C or °F % STEP mA

(Air intake absolute pressure – Atmospheric pressure) 0 deg 0.0% +20°C or +68°F 0 — 3% 0 STEP –0.2 — 0.2 mA

A/F sensor resistance value 1

A/F Sensor #1 Resistance

Ω

32 Ω

A/F sensor output lambda 1 A/F correction #3 A/F learning #3 Throttle motor duty Throttle motor voltage Sub throttle sensor voltage Main throttle sensor voltage

A/F Sensor #1 A/F Correction #3 A/F Learning #3 Throttle Motor Duty Throttle Motor Voltage Sub-Throttle Sensor Main-Throttle Sensor

— % % % V V V

1.0 0.3% 0.00% –15% (Battery voltage) 1.52 V 0.66 V

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents Sub accelerator sensor voltage Main acceleration sensor voltage

Display Sub-Accelerator Sensor Main-Accelerator Sensor

Unit of measure V V

Note (at idling) 0.68 V 0.68 V

Memory vehicle speed

Memorized Cruise Speed

km/h or MPH

0 km/h or 0 MPH

Fuel level sensor signal Engine oil temperature Oil switching solenoid valve duty RH Oil switching solenoid valve duty LH Oil switching solenoid valve current RH Oil switching solenoid valve current LH Variable valve lift lift mode #1 cylinder roughness monitor #2 cylinder roughness monitor #3 cylinder roughness monitor #4 cylinder roughness monitor Knock sensor correction

Fuel level resistance Oil Temperature OSV Duty R OSV Duty L OSV Current R OSV Current L VVL Lift Mode Roughness Monitor #1 Roughness Monitor #2 Roughness Monitor #3 Roughness Monitor #4 Knocking Correction

Ω °C % % mA mA — — — — — deg mmHg, kPa, inHg or psig — — —

2 — 96 Ω ≥ 85°C (after warm-up) 16.9% 16.9% 192 mA 192 mA 1 0 0 0 0 0.0 deg +7.7 mmHg, +1.1 kPa, +0.31 inHg or +0.15 psig ON/OFF OFF OFF

Fuel tank pressure signal

Fuel Tank Pressure

AT vehicle ID signal Delivery (test) mode terminal D-check require Flag

AT Vehicle ID Signal Test Mode Signal D-check Require Flag Delivery Mode Connector (Test Mode Connector) Neutral Position Switch Idle Switch Signal Ignition Switch P/S Switch Signal A/C Switch Starter Switch Rear O2 Rich Signal Knocking Signal Crankshaft Position Sig. Camshaft Position Sig. Rear Defogger SW Blower Fan SW Light Switch Radiator Fan Relay #1 Radiator Fan Relay #2 Fuel Pump Relay Vent. Solenoid Valve Eng. Oil Press. SW 1 Eng. Oil Press. SW 2 Retard Signal from AT Fuel Cut signal from AT



OFF

— — — — — — — — — — — — — — — — — — — — —

ON ON ON OFF (when OFF) OFF (when OFF) OFF Rich/Lean OFF ON ON OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) ON output OFF output ON ON OFF OFF

Ban of Torque Down



ON

Vehicle dynamics control (VDC) torque down demand

Request Torque Down VDC



OFF

AT coordinate permission signal

Torque permission signal



Allowed (prohibited on MT vehicles)

Delivery (test) mode terminal Neutral position switch signal Soft idle switch signal Ignition switch signal Power steering switch signal Air conditioning switch signal Starter switch signal Rear oxygen monitor Knocking signal Crankshaft position sensor signal Camshaft position sensor signal Rear defogger switch signal Blower fan switch signal Light switch signal Radiator fan relay 1 signal Radiator fan relay 2 signal Fuel pump relay signal Drain valve signal Variable valve lift diagnosis oil pressure switch signal 1 Variable valve lift diagnosis oil pressure switch signal 2 AT coordinate retard angle demand signal AT coordinate fuel cut demand signal Vehicle dynamics control (VDC) torque down prohibition output

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents Electronic throttle control motor relay signal Clutch switch signal Stop light switch signal SET/COAST switch signal RES/ACC switch signal Brake switch signal Main switch signal Body integrated unit data reception Body integrated unit counter update Cruise control cancel switch signal Malfunction indicator light signal Oil level switch

Display ETC Motor Relay Clutch Switch Stop Light Switch SET/COAST Switch RESUME/ACCEL Switch Brake Switch Main Switch Body Int. Unit Data Body Int. Unit Count CC Cancel SW MIL On Flag Oil level switch

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Unit of measure — — — — — — — — — — — —

Note (at idling) ON OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) ON ON OFF (when OFF) OFF (when unlit) HIGH level

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Subaru Select Monitor ENGINE (DIAGNOSTICS)

3. READ CURRENT DATA FOR ENGINE (OBD MODE) NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • A list of the support data is shown in the following table. Contents Number of diagnosis code Condition of malfunction indicator light Monitoring test of misfire Monitoring test of misfire

Display Number of Diag. Code: MI(MIL) Misfire monitoring (Supp) Misfire monitoring (Rdy) Fuel system monitoring (Supp)

Monitoring test of fuel system

Referential value (at idling) 0 OFF YES YES

Unit of measure — — — —

YES



Monitoring test of fuel system

Fuel system monitoring (Rdy)

YES



Monitoring test of comprehensive component

Component monitoring (Supp)

YES



Monitoring test of comprehensive component

Component monitoring (Rdy)

YES



YES NO NO N/A

— — — —

YES



Test of catalyst Test of catalyst Test of heating-type catalyst Test of heating-type catalyst Test of evaporative emission purge control system

Catalyst Diagnosis (Supp) Catalyst Diagnosis (Rdy) Heated catalyst (Supp) Heated catalyst (Rdy) Evaporative purge system (Supp)

Test of evaporative emission purge control system

Evaporative purge system (Rdy)

NO



Secondary air system test

Secondary air system (Supp)

NO



Secondary air system test

Secondary air system (Rdy)

N/A



Test of air conditioning system refrigerant

A/C system refrigerant (Supp)

NO



N/A



YES NO

— —

YES



NO YES NO Cl_normal 23.0 92

— — — — % °C

Short term fuel trim B1

–0.8

%

Long term fuel trim by front oxygen (A/F) sensor (Bank 1)

Long term fuel trim B1

0.0

%

Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal #1 Cylinder ignition timing Intake air temperature signal Intake air amount

Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow

28 700 0 16.0 36 2.7

kPa rpm km/h ° °C g/s

Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor Test of oxygen sensor heater Test of oxygen sensor heater Test of EGR system Test of EGR system Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1)

A/C system refrigerant (Rdy) Oxygen sensor (Supp) Oxygen sensor (Rdy) O2 Heater Diagnosis (Supp) O2 Heater Diagnosis (Rdy) EGR system (Supp) EGR system (Rdy) Fuel system for Bank 1 Calculated load value Coolant Temp.

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents Throttle position signal Oxygen sensor (Bank 1 Sensor 2) A/F correction (Bank 1 Sensor 2) On-board diagnostic system Front oxygen (A/F) sensor (Bank 1 Sensor 1) Oxygen sensor (Bank 1 Sensor 2) Elapsed time after engine start Travel distance after the malfunction indicator light illuminates

Display Throttle Opening Angle Oxygen sensor #12 Short term fuel trim #12 OBD System Oxygen sensor #11 Oxygen sensor #12 Time Since Engine Start

Referential value (at idling) 13 0.7 0.0 OBD/OBD2 Support Support —

Unit of measure % V % — — — sec

Lighted MI lamp history



km

A/F lambda signal (Bank 1 Sensor 1) A/F sensor output signal (Bank 1 Sensor 1) Target EGR EGR deviation Evaporative purge Fuel level signal Number of warm ups after DTC clear Travel distance after DTC clear Fuel tank pressure signal Atmospheric pressure signal A/F lambda signal (Bank 1 Sensor 1) A/F sensor current (Bank 1 Sensor 1) Catalyst temperature #1 Monitoring test of misfire Monitoring test of misfire

A/F Sensor #11 A/F Sensor #11 Commanded EGR EGR Error Commanded Evap Purge Fuel Level Number of warm-ups Meter since DTC cleared Fuel Tank Pressure Atmosphere Pressure A/F Sensor #11 A/F Sensor #11 Catalyst Temperature #11 Misfire monitoring (Enable) Misfire monitoring (Comp) Fuel system monitoring (Enable)

1.001 2.79 — — 0 — — — –32.00 Atmospheric pressure 1.001 0.00 — YES NO

— V % % % % — km Pa kPa — mA °C — —

YES



Monitoring test of fuel system Monitoring test of fuel system

Fuel system monitoring (Comp)

NO



Monitoring test of comprehensive component

Component monitoring (Enable)

YES



Monitoring test of comprehensive component

Component monitoring (Comp)

NO



YES



NO N/A N/A

— — —

Catalyst Diagnosis (Enable) Catalyst Diagnosis (Comp) Heated catalyst (Enable) Heated catalyst (Comp)

Test of catalyst Test of catalyst Test of heating-type catalyst Test of heating-type catalyst Test of evaporative emission purge control system

Evaporative purge system (Enable)

YES



Test of evaporative emission purge control system

Evaporative purge system (Comp)

NO



Secondary air system test

Secondary air system (Enable)

N/A



Secondary air system test

Secondary air system (Comp)

N/A



Test of air conditioning system refrigerant

A/C system refrigerant (Enable)

N/A



Test of air conditioning system refrigerant

A/C system refrigerant (Comp)

N/A



Test of oxygen sensor Test of oxygen sensor

Oxygen sensor (Enable) Oxygen sensor (Comp)

YES NO

— —

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents

Display O2 Heater Diagnosis (Enable)

Test of oxygen sensor heater

O2 Heater Diagnosis (Comp)

Test of oxygen sensor heater

Referential value (at idling)

Unit of measure

YES



NO



YES NO 13.789 22 0.976 2 Ambient air temperature 32 13 13 0

— — V % — % °C % % % %



min

Test of EGR system Test of EGR system ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Engine operating time while malfunction indicator light lit

EGR system (Enable) EGR system (Comp) Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont.

Elapsed time after DTC clear Type of fuel Relative acceleration opening angle

Time since DTC cleared Type of fuel Relative Accelera. Pos.

— GAS 0

min — %

Neutral condition

AT drive status/MT gear status

NEUT



Time while MIL lighted

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Subaru Select Monitor ENGINE (DIAGNOSTICS)

4. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE) NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • A list of the support data is shown in the following table. Description DTCs of freeze frame data Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor Long term fuel trim by front oxygen (A/F) sensor Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal Ignition timing advance for #1 cylinder Intake air temperature signal Intake air amount Throttle position signal Oxygen sensor (Bank 1 Sensor 2) A/F correction (Bank 1 Sensor 2) On-board diagnostic system Front oxygen (A/F) sensor (Bank 1 Sensor 1) Oxygen sensor (Bank 1 Sensor 2) Elapsed time after engine start Target EGR EGR deviation Evaporative purge Fuel level signal Fuel tank pressure signal Atmospheric pressure ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Neutral condition

Display Freeze frame data Fuel system for Bank 1 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Oxygen sensor #12 Short term fuel trim #12 OBD System Oxygen sensor #11 Oxygen sensor #12 Time Since Engine Start Commanded EGR EGR Error Commanded Evap Purge Fuel Level Fuel Tank Pressure Atmosphere Pressure Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont. AT drive status/MT gear status

5. V.I.N REGISTRATION 1) On «Main Menu» display, select {Each System Check}. 2) On «System Selection Menu» display, select {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On «Engine Diagnosis» display, select {Entry VIN}. 5) Perform the procedures shown on the display screen.

EN(H4SO)(diag)-40

Unit of measure — — % °C or °F % % mmHg, kPa, inHg or psig rpm km/h or MPH ° °C or °F g/s or lb/m % V % — — — sec % % % % mmHg, kPa, inHg or psig mmHg, kPa, inHg or psig V % — % °C or °F % % % % —

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Read Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10.Read Diagnostic Trouble Code (DTC) A: OPERATION 1. SUBARU SELECT MONITOR NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”.

2. GENERAL SCAN TOOL Refer to data denoting emission-related powertrain DTC. For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”. NOTE: Refer to general scan tool manufacturer’s instruction manual to access powertrain DTC (MODE $03).

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Inspection Mode ENGINE (DIAGNOSTICS)

11.Inspection Mode A: PROCEDURE Perform the diagnosis shown in the following DTC table. When performing the diagnosis not listed in “List of Diagnostic Trouble Code (DTC)”, refer to the item on the drive cycle. P0031 P0032 P0037 P0038 P0077 P0083 P0102 P0103 P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0131 P0132 P0137 P0138 P0140 P0182 P0183

DTC

Item HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) Intake Valve Control Solenoid Circuit High (Bank 1) Intake Valve Control Solenoid Circuit High (Bank 2) Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/Switch “A” Circuit Low Throttle/Pedal Position Sensor/Switch “A” Circuit High O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) Fuel Temperature Sensor “A” Circuit Low Input Fuel Temperature Sensor “A” Circuit High Input

P0197 P0198 P0222 P0223 P0327 P0328 P0335 P0336 P0340

Engine Oil Temperature Sensor Low Engine Oil Temperature Sensor High Throttle/Pedal Position Sensor/Switch “B” Circuit Low Throttle/Pedal Position Sensor/Switch “B” Circuit High Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor) Knock Sensor 1 Circuit High (Bank 1 or Single Sensor) Crankshaft Position Sensor “A” Circuit Crankshaft Position Sensor “A” Circuit Range/Performance Camshaft Position Sensor “A” Circuit (Bank 1 or Single Sensor)

— — — — — — — — —

P0341

Camshaft Position Sensor “A” Circuit Range/Performance (Bank 1 or Single Sensor)



P0447 P0448 P0452 P0453 P0458 P0462 P0463 P0500 P0512 P0513

Evaporative Emission Control System Vent Control Circuit Open Evaporative Emission Control System Vent Control Circuit Shorted Evaporative Emission Control System Pressure Sensor Low Input Evaporative Emission Control System Pressure Sensor High Input Evaporative Emission System Purge Control Valve Circuit Low Fuel Level Sensor “A” Circuit Low Fuel Level Sensor “A” Circuit High Vehicle Speed Sensor “A” Starter Request Circuit Incorrect Immobilizer Key

— — — — — — — — — —

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Condition — — — — — — — — — — — — — — — — — — — — — — —

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Inspection Mode ENGINE (DIAGNOSTICS) DTC P0604 P0605 P0607 P0638 P0700 P0851 P0852 P1152 P1153 P1160 P1518 P1560 P1570 P1571 P1572 P1574 P1576 P1577 P1578 P2101 P2102 P2103 P2109 P2122 P2123 P2127 P2128 P2135 P2138 P2227 P2228 P2229

Item Internal Control Module Random Access Memory (RAM) Error Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/Performance (Bank 1) Transmission Control System (MIL Request) Park/Neutral Switch Input Circuit Low Park/Neutral Switch Input Circuit High O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) Return Spring Failure Starter Switch Circuit Low Input Back-Up Voltage Circuit Malfunction Antenna Reference Code Incompatibility IMM Circuit Failure Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Throttle Actuator Control Motor Circuit Range/Performance Throttle Actuator Control Motor Circuit Low Throttle Actuator Control Motor Circuit High Throttle/Pedal Position Sensor “A” Minimum Stop Performance Throttle/Pedal Position Sensor/Switch “D” Circuit Low Input Throttle/Pedal Position Sensor/Switch “D” Circuit High Input Throttle/Pedal Position Sensor/Switch “E” Circuit Low Input Throttle/Pedal Position Sensor/Switch “E” Circuit High Input Throttle/Pedal Position Sensor/Switch “A”/“B” Voltage Correlation Throttle/Pedal Position Sensor/Switch “D”/“E” Voltage Correlation Atmospheric Pressure Sensor Range/Performance Barometric Pressure Circuit Low Barometric Pressure Circuit High

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Condition — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

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Inspection Mode ENGINE (DIAGNOSTICS)

1. PREPARATION FOR THE INSPECTION MODE 1) Check battery voltage is more than 12 V and fuel remains half [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8 Imp gal)]. 2) Lift up the vehicle using a garage jack and place it on rigid racks, or drive the vehicle onto free rollers. WARNING: • Before lifting up the vehicle, ensure parking brakes are applied. • Do not use a pantograph jack in place of a rigid rack. • Secure a rope or wire to the front or rear towing hooks to prevent the lateral runout of front wheels. • Before rotating the wheels, make sure that there is no one in front of the vehicle. Besides while the wheels are rotating, make sure that no one approaches the vehicle front side. • Make sure that there is nothing around the wheels. For AWD model, pay special attention to all four wheels. • While servicing, do not depress or release the clutch pedal or accelerator pedal quickly regardless of the engine speed. Quick operation may cause the vehicle to drop off the free roller. • To prevent the vehicle from slipping due to vibration, do not place anything between rigid rack and the vehicle.

2. SUBARU SELECT MONITOR 1) Check that no DTC remains after clearing memory. 2) Warm up the engine. 3) Prepare the Subaru Select Monitor kit.

EN-05692

4) Prepare PC with Subaru Select Monitor installed. 5) Connect the USB cable to SDI (Subaru Diagnosis Interface) and USB port on the personal computer (dedicated port for the Subaru Select Monitor). NOTE: The dedicated port for the Subaru Select Monitor means the USB port which was used to install the Subaru Select Monitor. 6) Connect the diagnosis cable to SDI. 7) Install the delivery (test) mode fuse (A) of the fuse box.

(A)

(A) EN-07555

(B)

EN-00041

(A) Rigid rack (B) Free roller

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Inspection Mode ENGINE (DIAGNOSTICS)

8) Connect SDI to data link connector located in the lower portion of the instrument panel (on the driver’s side). CAUTION: Do not connect any scan tools except Subaru Select Monitor or general scan tool.

3. GENERAL SCAN TOOL 1) After performing the diagnostics and clearing the memory, check that no DTC remains. 2) Warm up the engine. 3) Install the delivery (test) mode fuse (A) of the main fuse box.

(A)

EN-07712

9) Start the PC. 10) Turn the ignition switch to ON (engine OFF) and run the “PC application for Subaru Select Monitor”. 11) On «Main Menu» display, select {Each System Check}. 12) On «System Selection Menu» display, select {Engine Control System}. 13) Click the [OK] button after the information of engine type has been displayed. 14) On «Engine Diagnosis» display, select {Dealer Check Mode Procedure}. 15) When the «Perform Inspection (Dealer Check) Mode?» is shown on the screen, click the [Next] button. 16) Perform subsequent procedures as instructed on the display screen. • If trouble still remains in the memory, the corresponding DTC appears on the display screen. NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”. • Release the parking brake. • The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When engine control system diagnosis is finished, perform the VDC memory clearance procedure of self-diagnosis function.

EN-07555

4) Connect the general scan tool to the data link connector located in the lower portion of the instrument panel (on the driver’s side). CAUTION: Do not connect any scan tools except Subaru Select Monitor or general scan tool.

EN-07712

5) Start the engine. NOTE: • Make sure the select lever is placed in “P” position before starting. (CVT model) • Depress the clutch pedal when starting engine. (MT model) 6) Turn the neutral position switch to ON operating select lever or shift lever. 7) Depress the brake pedal to turn the brake switch ON. (CVT model) 8) Keep the engine speed in 2,500 — 3,000 rpm range for 40 seconds.

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Inspection Mode ENGINE (DIAGNOSTICS)

9) Place the select lever or shift lever in “D” position (CVT model) or “1st gear” (MT model) and drive the vehicle at 5 to 10 km/h (3 to 6 MPH). NOTE: • For AWD model, release the parking brake. • The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When engine control system diagnosis is finished, perform the VDC memory clearance procedure of self-diagnosis function. 10) Using the general scan tool, check for DTC and record the result(s). NOTE: • For detailed operation procedures, refer to the general scan tool operation manual. • For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”.

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Drive Cycle ENGINE (DIAGNOSTICS)

12.Drive Cycle A: PROCEDURE It is necessary to perform the drive cycle listed below if DTC is not found in the Inspection Mode. It is possible to complete diagnosis of the DTC by performing the indicated drive cycle. After the repair for the DTC, perform a necessary drive cycle and make sure the function recovers and the DTC is recorded.

1. PREPARATION FOR DRIVE CYCLE 1) Check that the battery voltage is 12 V or more and fuel remains approx. half [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8 Imp gal)]. 2) After performing the diagnostics and Clear Memory Mode, check that no DTC remains. 3) Check the delivery (test) mode fuse is removed. NOTE: • Perform the drive cycle after warming up the engine except when the engine coolant temperature at engine start is specified. • Perform the drive cycle twice if the DTC in the list is marked with *. After completing the first drive cycle, stop the engine and perform second diagnosis in same condition.

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Drive Cycle ENGINE (DIAGNOSTICS)

2. DRIVE CYCLE A DTC

Item

*P0125

Insufficient Coolant Temperature for Closed Loop Fuel Control

*P0126

Insufficient Engine Coolant Temperature for Stable Operation Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature)

*P0128 *P0133 *P0141

O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) O2 Sensor Heater Circuit (Bank1 Sensor2)

*P0171

System Too Lean (Bank 1)

*P0172

System Too Rich (Bank 1)

*P0196

Engine Oil Temperature Sensor Circuit Range/Performance

*P0301

Cylinder 1 Misfire Detected

*P0302

Cylinder 2 Misfire Detected

*P0303

Cylinder 3 Misfire Detected

*P0304

Cylinder 4 Misfire Detected

*P0420

Catalyst System Efficiency Below Threshold (Bank 1)

*P0442

Evaporative Emission Control System Leak Detected (Small Leak)

*P0451

Evaporative Emission Control System Pressure Sensor

*P0456

Evaporative Emission Control System Leak Detected (Very Small Leak)

*P0457

Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off)

*P0459 P1443

Evaporative Emission System Purge Control Valve Circuit High Vent Control Solenoid Valve Function Problem

*P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

*P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

Condition Engine coolant temperature at engine start is less than 20°C (68°F). — — — — Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. — Complete diagnosis with drive cycle B or C as well.

Diagnostic procedure: 1) Drive for 20 minutes at a constant speed of 80 km/h (50 MPH). 2) Stop the vehicle and idle for one minute.

EN(H4SO)(diag)-48

Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. — Engine coolant temperature at engine start is less than 30°C (86°F). — Engine coolant temperature at engine start is less than 30°C (86°F). Engine coolant temperature at engine start is less than 30°C (86°F). — — Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well.

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Drive Cycle ENGINE (DIAGNOSTICS)

3. DRIVE CYCLE B DTC

Item

Condition Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well.

*P0171

System Too Lean (Bank 1)

*P0172

System Too Rich (Bank 1)

*P0301

Cylinder 1 Misfire Detected

*P0302

Cylinder 2 Misfire Detected

Complete diagnosis with drive cycle A or C as well.

*P0303

Cylinder 3 Misfire Detected

Complete diagnosis with drive cycle A or C as well.

*P0304

Cylinder 4 Misfire Detected

*P0464 *P0506 *P0507

Fuel Level Sensor Circuit Intermittent Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected

*P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

Complete diagnosis with drive cycle A or C as well.

*P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

Complete diagnosis with drive cycle A or C as well.

Diagnostic procedure: 1) Drive at 10 km/h (6 MPH) or more. 2) Stop the vehicle and idle for ten minutes.

EN(H4SO)(diag)-49

Complete diagnosis with drive cycle A or C as well. — — —

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Drive Cycle ENGINE (DIAGNOSTICS)

4. DRIVE CYCLE C DTC P0026 P0028 *P0030 *P0068 P0076 P0082 *P0101 P0134 *P0139

Item Intake Valve Control Solenoid Circuit Range/Performance (Bank 1) Intake Valve Control Solenoid Circuit Range/Performance (Bank 2) HO2S Heater Control Circuit (Bank 1 Sensor 1) MAP/MAF - Throttle Position Correlation Intake Valve Control Solenoid Circuit Low (Bank 1) Intake Valve Control Solenoid Circuit Low (Bank 2) Mass or Volume Air Flow Circuit Range/Performance O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)

Condition — — — — — — — — —

*P0171

System Too Lean (Bank 1)

*P0172

System Too Rich (Bank 1)

*P0301

Cylinder 1 Misfire Detected

*P0302

Cylinder 2 Misfire Detected

Complete diagnosis with drive cycle A or B as well.

*P0303

Cylinder 3 Misfire Detected

Complete diagnosis with drive cycle A or B as well.

*P0304

Cylinder 4 Misfire Detected

*P0400 P1492 P1493 P1494 P1495 P1496 P1497 P1498 P1499

Exhaust Gas Recirculation Flow EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input)

*P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

Complete diagnosis with drive cycle A or B as well.

*P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

Complete diagnosis with drive cycle A or B as well.

Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well.

EN(H4SO)(diag)-50

Complete diagnosis with drive cycle A or B as well. — — — — — — — — —

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Drive Cycle ENGINE (DIAGNOSTICS)

Diagnostic procedure: Drive according to the drive pattern described below. (H)

(C)

97 (60)

(D) 64 (40)

(G)

(F)

(E)

(B)

(A) 0

50

100

(I)

150

EN-00842

(A) (B) (C)

Idle the engine for 10 seconds or more. Accelerate the vehicle to 97 km/h (60 MPH) within 20 seconds. Drive the vehicle at 97 km/h (60 MPH) for 20 seconds.

(D) (E) (F)

Decelerate the vehicle to 64 km/h (40 MPH) with throttle fully closed. Drive the vehicle at 64 km/h (40 MPH) for 20 seconds. Accelerate the vehicle to 97 km/h (60 MPH) within 10 seconds.

(G) (H)

Stop the vehicle with throttle fully closed. Vehicle speed km/h (MPH)

(I)

Sec.

5. DRIVE CYCLE D DTC *P0181

Item Fuel Temperature Sensor “A” Circuit Range/Performance

Condition —

NOTE: In drive cycle D, one drive cycle will be established when both the drift diagnosis and stuck diagnosis have completed. Diagnostic procedure: DRIFT DIAGNOSIS 1) Make sure of the items below before starting the engine. • Engine coolant temperature is less than 30°C (86°F). • Remaining fuel is 10 2 (2.6 US gal, 2.2 Imp gal) or more. • Battery voltage is 10.9 V or more. 2) Idle the engine until engine coolant temperature is at least 10°C (18°F) higher than it was when engine started. 3) After the engine has reached the state of procedure 2), idle the engine for another 5 minutes or more. STUCK DIAGNOSIS 1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. 3) Drive the vehicle for the distance equal to the fuel of 50 2 (13.2 US gal, 11 Imp gal). NOTE: • It is acceptable to drive the vehicle intermittently. • Do not disconnect the battery terminals during stuck diagnosis. (Data will be cleared by disconnecting the battery terminals.)

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Drive Cycle ENGINE (DIAGNOSTICS)

6. DRIVE CYCLE E DTC *P0461

Item Fuel Level Sensor “A” Circuit Range/Performance

Condition —

Diagnostic procedure: 1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. 3) Drive the vehicle for the distance equal to the fuel of 30 2 (7.9 US gal, 6.6 Imp gal). NOTE: • It is acceptable to drive the vehicle intermittently. • Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)

7. DRIVE CYCLE F DTC *P0111

Item Intake Air Temperature Sensor 1 Circuit Range/Performance

Condition —

Diagnostic procedure: 1) Make sure that the engine coolant temperature is less than 30°C (86°F). 2) Drive according to the drive pattern described below. (A)

(2)

(4)

(6)

80 km/h (50 MPH)

0

(3)

(5)

(7)

(B)

(1) EN-07588

(A)

Vehicle speed

(B)

Elapsed time

(1)

Idle the engine for 10 seconds after engine start. Drive for 8 minutes at a constant speed of 80 km/h (50 MPH). Stop the vehicle and idle for 30 seconds.

(4)

Drive for 30 seconds at a constant speed of 80 km/h (50 MPH). Stop the vehicle and idle for 30 seconds.

(2) (3)

(5)

(6) (7)

Drive for 30 seconds at a constant speed of 80 km/h (50 MPH). Stop the vehicle and idle for 30 seconds.

NOTE: • There is no given transition time between idling and cruising. • Driving at constant speed only on a downhill causes smaller engine load and may result in failure to obtain a right diagnostic result. • When the engine stops while performing drive cycle F, perform it again from the state of procedure 1).

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Drive Cycle ENGINE (DIAGNOSTICS)

8. DRIVE CYCLE H DTC *P1602

Item Control Module Programming Error

Condition —

Diagnostic procedure: 1) Perform the Clear Memory Mode. 2) With the ignition switch ON (engine OFF), read the engine coolant temperature, intake air temperature and fuel temperature. 3) If the values from step 2) satisfy the following two conditions, idle the engine for one minute.

Condition: | Engine coolant temperature — Intake air temperature | ≤ 5°C (41°F) | Engine coolant temperature — Fuel temperature | ≤ 2°C (36°F) NOTE: • If the conditions are not satisfied, turn the ignition switch to OFF and wait until the parameters are satisfied. • For CVT models, hold the select lever to “P” range or “N” range at idling, and for MT models, the shift lever in the neutral position at idling.

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Clear Memory Mode ENGINE (DIAGNOSTICS)

13.Clear Memory Mode A: OPERATION 1. SUBARU SELECT MONITOR NOTE: • Initial diagnosis of electronic throttle control is performed after memory clearance. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine. • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

2. GENERAL SCAN TOOL For clear memory procedures using the general scan tool, refer to “General Scan Tool Instruction Manual”. NOTE: Initial diagnosis of electronic throttle control is performed after memory clearance. For this reason, start the engine after 10 seconds or more have elapsed since the ignition switch was turned to ON.

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System Operation Check Mode ENGINE (DIAGNOSTICS)

14.System Operation Check Mode A: OPERATION CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. NOTE: For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

15.Malfunction Indicator Light A: PROCEDURE 1. Activation of malfunction indicator light. ↓ 2. Malfunction indicator light does not come on. ↓ 3. Malfunction indicator light does not go off. ↓ 4. Malfunction indicator light does not blink. ↓ 5. Malfunction indicator light remains blinking.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

B: ACTIVATION OF MALFUNCTION INDICATOR LIGHT 1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light (A) in the combination meter illuminates. NOTE: If the malfunction indicator light does not illuminate, perform diagnostics of the malfunction indicator light circuit or the combination meter circuit.

3) If the diagnostic system detects a misfire which could damage the catalyst, the malfunction indicator light will blink at a cycle of 1 Hz. (1) (2) (3) (4) (6) (5) EN-01680

(1) (2) (3) (4) (5) (6)

CHECK ENGINE

CHECK ENGINE

(A) EN-07714

ON OFF Ignition switch ON Engine start Misfire start 1 second

4) Install the delivery (test) mode fuse (A) with ignition switch to OFF.

2) After starting the engine, the malfunction indicator light goes out. If it does not go off, any of the engine and emission control system has malfunction.

(A)

(1) (3) (4) (2) (3) (4)

EN-07555 (5) (6)

(1) No faulty (2) Trouble occurs (3) ON

EN-01679

(1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light illuminates. (2) After the engine starts, malfunction indicator light blinks in a cycle of 0.5 Hz. (During diagnosis)

(4) OFF (5) Ignition switch ON (6) Engine start

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

(3) Malfunction indicator light blinks at a cycle of 3 Hz after diagnosis if there is no trouble. Malfunction indicator light illuminates if faulty. (1) (2) (4)

(3)

EN-01681

(1) (2) (3) (4)

ON OFF Ignition switch ON 1 second

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON DIAGNOSIS: The malfunction indicator light circuit is open or shorted. TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), malfunction indicator light does not illuminate. WIRING DIAGRAM: B72

IGNITION SWITCH

BATTERY

F/B No. 5

SBF-5 1

MAIN SBF

3

19

E

COMBINATION METER

6

i10

M/B DELIVERY (TEST) MODE FUSE No. 36 1 2

B138

* *

18

i3

B : B135

C : B136

ECM

i10

B138

1 2 3 4 5 6 7 8

: TERMINAL No. OPTIONAL ARRANGEMENT

C4

B33

C34

B38

*

B:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

B72

B38

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B135

C:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

EN-07700

1

Step Check Is the voltage 10 V or more? CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 33 (+) — Chassis ground (–):

EN(H4SO)(diag)-59

Yes Go to step 5.

No Go to step 2.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

2

3

4

5

6

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. COMBINATION METER CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the combination meter. 3) Disconnect the connector from ECM and combination meter. 4) Measure the resistance of harness between ECM and combination meter connector. Connector & terminal (B135) No. 33 — (i10) No. 6: CHECK FOR POOR CONTACT. Check for poor contact of combination meter connector.

Is there poor contact of combi- Repair the poor nation meter connector? contact of combination meter connector. CHECK HARNESS BETWEEN COMBINAIs the voltage 10 V or more? Replace the meter TION METER AND IGNITION SWITCH CONcase assembly of NECTOR. combination meter. 1) Turn the ignition switch to ON.

Connector & terminal (i10) No. 19 (+) — Chassis ground (–):

CHECK FOR POOR CONTACT. Check for poor connection by shaking or pulling ECM harness. CHECK ECM CONNECTOR. Check the connection of ECM connector.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and combination meter connector • Poor contact of coupling connector Go to step 4.

Check the following item and repair if necessary. NOTE: • Blown-out of fuse (F/B No. 5) • Open circuit or short circuit to ground in harness of power supply circuit Go to step 6.

Does the malfunction indicator Repair the poor light illuminate? contact of ECM connector. Is the ECM connector correctly Replace the ECM. Repair the connecconnected?

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF DIAGNOSIS: The malfunction indicator light circuit is shorted. TROUBLE SYMPTOM: Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select Monitor or general scan tool display. WIRING DIAGRAM: B72

IGNITION SWITCH

BATTERY

F/B No. 5

SBF-5 1

MAIN SBF

3

19

E

COMBINATION METER

6

i10

M/B DELIVERY (TEST) MODE FUSE No. 36 1 2

B138

* *

18

i3

B : B135

C : B136

ECM

i10

B138

1 2 3 4 5 6 7 8

: TERMINAL No. OPTIONAL ARRANGEMENT

C4

B33

C34

B38

*

B:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

B72

B38

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C:

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

EN-07700

1

Step CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Turn the ignition switch to ON.

Check Yes Does the malfunction indicator Repair the ground light illuminate? short circuit of harness between ECM and combination meter connector.

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No Replace the ECM.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • The delivery (test) mode fuse circuit is open. TROUBLE SYMPTOM: Malfunction indicator light does not blink during Inspection Mode. WIRING DIAGRAM: B72

IGNITION SWITCH

BATTERY

F/B No. 5

SBF-5 1

MAIN SBF

3

19

E

COMBINATION METER

6

i10

M/B DELIVERY (TEST) MODE FUSE No. 36 1 2

B138

* *

18

i3

B : B135

C : B136

ECM

i10

B138

1 2 3 4 5 6 7 8

: TERMINAL No. OPTIONAL ARRANGEMENT

C4

B33

C34

B38

*

B:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

B72

B38

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C:

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

EN-07700

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator Go to step 2. CATOR LIGHT. light illuminate? 1) Turn the ignition switch to OFF. 2) Check the delivery (test) mode fuse is removed. 3) Turn the ignition switch to ON. (engine OFF)

No Repair the malfunction indicator light circuit. CHECK HARNESS BETWEEN ECM AND Does the malfunction indicator Repair the ground Go to step 3. COMBINATION METER CONNECTOR. light illuminate? short circuit of har1) Turn the ignition switch to OFF. ness between 2) Disconnect the connector from ECM. ECM and combi3) Turn the ignition switch to ON. nation meter connector. CHECK HARNESS BETWEEN ECM AND DE- Is the resistance less than 1 Ω? Go to step 4. Repair the harness LIVERY (TEST) MODE FUSE. and connector. 1) Turn the ignition switch to OFF. NOTE: 2) Install the delivery (test) mode fuse of the In this case, repair main fuse box. the following item: 3) Measure the resistance of harness between • Open circuit of ECM connectors. harness between Connector & terminal ECM and delivery (B136) No. 34 — (B136) No. 4: (test) mode fuse • Poor contact of joint connector CHECK FOR POOR CONTACT. Is there poor contact of ECM Repair the poor Replace the ECM. Check for poor contact of ECM connector. connector? contact of ECM

EN(H4SO)(diag)-63

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING DIAGNOSIS: The delivery (test) mode fuse circuit is shorted. TROUBLE SYMPTOM: Malfunction indicator light blinks when delivery (test) mode fuse is not connected. WIRING DIAGRAM: B72

IGNITION SWITCH

BATTERY

F/B No. 5

SBF-5 1

MAIN SBF

3

19

E

COMBINATION METER

6

i10

M/B DELIVERY (TEST) MODE FUSE No. 36 1 2

B138

* *

18

i3

B : B135

C : B136

ECM

i10

B138

1 2 3 4 5 6 7 8

: TERMINAL No. OPTIONAL ARRANGEMENT

C4

B33

C34

B38

*

B:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

B72

B38

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C:

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

EN-07700

1

Step CHECK DELIVERY (TEST) MODE FUSE. 1) Check the delivery (test) mode fuse is removed. 2) Turn the ignition switch to ON.

Check Yes Does the malfunction indicator Go to step 2. light blink?

EN(H4SO)(diag)-64

No System is normal. NOTE: Malfunction indicator light blinks when delivery (test) mode fuse is connected.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? CHASSIS GROUND. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B136) No. 34 — Chassis ground:

EN(H4SO)(diag)-65

Yes Repair the short circuit to ground in harness between ECM and delivery (test) mode fuse.

No Replace the ECM.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

16.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Check of the fuel amount ↓ 2. Inspection of starter motor circuit. ↓ 3. Inspection of ECM power supply and ground line. ↓ 4. Inspection of ignition control system. ↓ 5. Inspection of fuel pump circuit. ↓ 6. Inspection of fuel injector circuit.

EN(H4SO)(diag)-66

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

B: STARTER MOTOR CIRCUIT CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: F/B No. 21 6

BATTERY MAIN SBF

SBF-5

4

2

2 B72

3 IGNITION SWITCH

STARTER RELAY

E

3

1

B493

INHIBITOR SWITCH P CVT

MT

12

2

CVT

MT

11

1

D

T7 STARTER MOTOR

CVT

B501

N

9 T3

MT

CLUTCH STROKE SENSOR (CLUTCH START SWITCH)

B12

R

6

CVT B14

M C16

B26

MT

B : B135 ECM C : B136

B493

B501

B72

1 2 3 4

1 2 3 4 5

1 2 3 4 5 6

T7

B12

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9 10 11 12

C : B136

B : B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07701

1 2

Step Check CHECK BATTERY. Is the voltage 12 V or more? Check the battery voltage. CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate? NOTE: Make sure the security alarm does not sound.

EN(H4SO)(diag)-67

Yes Go to step 2. Go to step 3.

No Charge or replace the battery. Go to step 4.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step 3

CHECK DTC.

4

CHECK INPUT SIGNAL FOR STARTER MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from starter motor. 3) Turn the ignition switch to START. 4) Measure the voltage between the starter motor connector and the engine ground. Connector & terminal (B14) No. 1 (+) — Engine ground (–): NOTE: For CVT model, place the select lever in “P” range or “N” range. For MT model, depress the clutch pedal. CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ignition switch. 3) Measure the voltage between ignition switch connector and chassis ground. Connector & terminal (B72) No. 3 (+) — Chassis ground (–): CHECK IGNITION SWITCH. Measure the resistance between ignition switch terminals after turning the ignition switch to START position. Terminals No. 3 — No. 2: No. 3 — No. 6: CHECK INPUT VOLTAGE OF STARTER RELAY. 1) Turn the ignition switch to OFF. 2) Remove the starter relay. 3) Connect the connector to ignition switch. 4) Measure the input voltage between starter relay connector and chassis ground after turning the ignition switch to START position. Connector & terminal (B493) No. 2 (+) — Chassis ground (–): (B493) No. 4 (+) — Chassis ground (–):

5

6

7

Check Is DTC displayed?

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Is the voltage 10 V or more?

Check the starter motor.

Is the voltage 10 V or more?

Go to step 6.

No The circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 5.

Repair the power supply circuit.

Is the resistance less than 1 Ω? Go to step 7.

Replace the ignition switch.

Is the voltage 10 V or more?

Repair open or short circuit to ground in harness between starter relay and ignition switch connector.

EN(H4SO)(diag)-68

Go to step 8.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

8

9

10 11

12

Step CHECK STARTER RELAY. 1) Connect the battery to starter relay terminals No. 1 and No. 2. 2) Measure the resistance between starter relay terminals. Terminals No. 3 — No. 4: CHECK HARNESS BETWEEN ECM AND STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness connector between ECM and starter relay. Connector & terminal (B493) No. 1 — (B135) No. 26: CHECK TRANSMISSION TYPE. CHECK ECM INPUT VOLTAGE. 1) Turn the ignition switch to START. 2) Measure the input voltage between ECM and chassis ground. Connector & terminal (B135) No. 26 (+) — Chassis ground (–): CHECK HARNESS BETWEEN STARTER RELAY AND INHIBITOR SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from inhibitor switch. 3) Measure the resistance of harness between the starter relay and inhibitor switch. Connector & terminal (B493) No. 3 — (T7) No. 6:

Check Yes Is the resistance less than 1 Ω? Go to step 9.

No Replace the starter relay.

Is the resistance less than 1 Ω? Go to step 10.

Repair the open circuit of harness between ECM and starter relay connector.

Is the transmission type CVT? Go to step 11. Is the voltage 10 V or more? Go to step 12.

Go to step 15. Repair the open circuit of harness between ECM and ignition switch connector.

Is the resistance less than 1 Ω? Go to step 13.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between starter relay connector and inhibitor switch connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between inhibitor switch connector and starter motor • Poor contact of coupling connector Replace the inhibitor switch.

13

CHECK HARNESS BETWEEN INHIBITOR Is the resistance less than 1 Ω? Go to step 14. SWITCH AND STARTER MOTOR. Measure the resistance of harness between the inhibitor switch and starter motor. Connector & terminal (T7) No. 9 — (B14) No. 1:

14

CHECK INHIBITOR SWITCH. 1) Place the select lever in “P” range or “N” range. 2) Measure the resistance between inhibitor switch terminals. Terminals No. 6 — No. 9:

Is the resistance less than 1 Ω? Check the ECM power supply and ground line.

EN(H4SO)(diag)-69

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

15

16

17

18

Step CHECK HARNESS BETWEEN IGNITION SWITCH AND CLUTCH STROKE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from clutch stroke sensor. 3) Turn the ignition switch to START. 4) Measure the voltage between clutch stroke sensor connector and chassis ground. Connector & terminal (B501) No. 2 (+) — Chassis ground (–): CHECK CLUTCH STROKE SENSOR. Measure the resistance between clutch stroke sensor terminals while depressing the clutch. Terminals No. 1 — No. 2: CHECK HARNESS BETWEEN ECM AND CLUTCH STROKE SENSOR CONNECTOR. Measure the resistance of harness between ECM and clutch stroke sensor connector. Connector & terminal (B135) No. 26 — (B501) No. 1: CHECK HARNESS BETWEEN STARTER RELAY AND STARTER MOTOR. Measure the resistance of harness between starter relay connector and starter motor. Connector & terminal (B493) No. 3 — (B14) No. 1:

Check Is the voltage 10 V or more?

Yes Go to step 16.

Is the resistance less than 1 Ω? Go to step 17.

Is the resistance less than 1 Ω? Go to step 18.

Is the resistance less than 1 Ω? Check the ECM power supply and ground line.

EN(H4SO)(diag)-70

No Repair the open circuit in harness between ignition switch connector and clutch stroke sensor connector.

Replace the clutch stroke sensor.

Repair the open circuit of harness between ECM and clutch stroke sensor connector. Repair the open circuit of the harness between starter relay connector and starter motor.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM) CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY M/B No. 16 4 3

M/B No. 12

1 2

IGNITION SWITCH

B72

B220

BATTERY

F/B No. 12

SBF-5 3

C2 C30

B13 C1 D7

1

MAIN SBF

A : B134

E

B : B135 ECM C : B136

37 36 40 35 34

D3 A6 A4 A3 D1

D : B137

B21 E2

E

E

B21

A: 1 8 9 18 19 28 29

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

B:

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B220

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

41 47 54

B72

1 2 3 4 5 6

1

2 10 20 30

C:

D:

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

Step Check Yes CHECK MAIN RELAY. Is the resistance less than 1 Ω? Go to step 2. 1) Turn the ignition switch to OFF. 2) Remove the main relay. 3) Connect the battery to main relay terminals No. 1 and No. 2. 4) Measure the resistance between main relay terminals. Terminals No. 3 — No. 4:

EN(H4SO)(diag)-71

EN-07702

No Replace the main relay.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

2

3

4

5

6

Step Check Yes CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? Go to step 3. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 2 (+) — Chassis ground (–): (B136) No. 30 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF MAIN RELAY. Measure the voltage between main relay connector and chassis ground. Connector & terminal (B220) No. 1 (+) — Chassis ground (–): (B220) No. 4 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to OFF. 2) Install the main relay. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 13 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to OFF. 2) Connect the connector to ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 1 (+) — Chassis ground (–): (B137) No. 7 (+) — Chassis ground (–):

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and engine ground terminal • Poor contact of coupling connector Repair the open or ground short circuit of harness of power supply circuit.

Is the voltage 10 V or more?

Go to step 4.

Is the voltage 10 V or more?

Go to step 5.

Repair the open or ground short circuit of harness of power supply circuit.

Is the voltage 10 V or more?

Go to step 6.

Repair the open circuit in harness between ECM and main relay connector.

Is the voltage 10 V or more?

Check ignition control system.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and main relay connector • Poor contact of main relay connector • Poor contact of ECM connector

EN(H4SO)(diag)-72

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

D: IGNITION CONTROL SYSTEM CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

31

22

21

ECM

32

B134

M/B No. 14

E

IG RELAY

11

5

33

B21

32

B220

49

8 7

E2

3

2

E34 1

3

2

3

2

1

3

2

1

E33 1

E32

E31

E

IGNITION COIL No. 1

E31

E33

B21

E32

E34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3

34 42

35 43 48

36 49

37 44 50

IGNITION COIL No. 3

IGNITION COIL No. 4

B220

38 45 51

IGNITION COIL No. 2

39 52

40 46 53

1 3 4 2

5 7 8 6

9 11 12 10

B134

13 15 16 14

17 18 20 21 19

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

41 47 54

EN-07703

1

Step Check Yes CHECK SPARK PLUG CONDITION. Is the spark plug condition nor- Go to step 2. 1) Remove the spark plug. 2) Check the spark plug condition.

EN(H4SO)(diag)-73

No Replace the spark plug.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

2

3

4

5

6

7

Step Check CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cylin1) Connect the spark plug to ignition coil. der? 2) Release the fuel pressure. 3) Contact the spark plug thread portion to engine. 4) While opening the throttle valve fully, crank the engine to check that spark occurs at each cylinder. CHECK IGNITION COIL POWER SUPPLY Is the voltage 10 V or more? CIRCUIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ignition coil. 3) Turn the ignition switch to ON. 4) Measure the voltage between ignition coil connector and engine ground. Connector & terminal (E31) No. 1 (+) — Engine ground (–): (E32) No. 1 (+) — Engine ground (–): (E33) No. 1 (+) — Engine ground (–): (E34) No. 1 (+) — Engine ground (–):

Yes No Check fuel pump Go to step 3. system.

Go to step 4.

CHECK HARNESS OF IGNITION COIL Is the resistance less than 5 Ω? Go to step 5. GROUND CIRCUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between ignition coil connector and engine ground. Connector & terminal (E31) No. 3 — Engine ground: (E32) No. 3 — Engine ground: (E33) No. 3 — Engine ground: (E34) No. 3 — Engine ground: CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Ω? Go to step 6. NITION COIL CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and ignition coil connector. Connector & terminal (B134) No. 21 — (E31) No. 2: (B134) No. 22 — (E32) No. 2: (B134) No. 31 — (E33) No. 2: (B134) No. 32 — (E34) No. 2: CHECK HARNESS BETWEEN ECM AND IGNITION COIL CONNECTOR. Measure the resistance of harness between ECM and engine ground. Connector & terminal: (B134) No. 21 — Engine ground: (B134) No. 22 — Engine ground: (B134) No. 31 — Engine ground: (B134) No. 32 — Engine ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Is the resistance 1 MΩ or more?

Go to step 7.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

EN(H4SO)(diag)-74

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in harness of power supply circuit • Poor contact of coupling connector • Blown out of fuse (M/B No. 14) Repair the open circuit in harness between ignition coil connector and engine grounding terminal.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and ignition coil connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and ignition coil connector.

Replace the ignition coil.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

E: FUEL PUMP CIRCUIT CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: M/B No. 20

B72

IGNITION SWITCH

BATTERY SBF-5

F/B No. 12 1

FUEL PUMP RELAY 21 17 19 20

MAIN SBF

3

33 B136

E ECM

B220

14

B38 i3

2

i155 R333 FUEL PUMP

M

5

1

6

2

R58

R57

R15

E

R58

B72

1 2 3 4 5 6

1 2 3 4 5 6

B38

B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B220 5 6 14 15 16 25 26 27 33 34 35

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

i155 R57 1 3

1

2 4 5 6 7 8 9 10 11

EN-07704

Step Check CHECK OPERATING SOUND OF FUEL Does the fuel pump emit operPUMP. ating sound? Check if the fuel pump operates for two seconds when turning the ignition switch to ON. NOTE: Fuel pump operation can be executed using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

EN(H4SO)(diag)-75

Yes Check the fuel injector circuit.

No Go to step 2.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

2

3

4

5

6

7

8

Step Check Yes CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5 Ω? Go to step 3. 1) Turn the ignition switch to OFF. 2) Remove the fuel pump access hole lid. 3) Disconnect the connector from fuel pump. 4) Measure the resistance of harness connector between fuel pump and chassis ground. Connector & terminal (R58) No. 6 — Chassis ground:

CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage 10 V or more? 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel pump connector and chassis ground. Connector & terminal (R58) No. 5 (+) — Chassis ground (–): CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 Ω? AND FUEL PUMP RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel pump connector and fuel pump relay connector. Connector & terminal (R58) No. 5 — (B220) No. 20:

Replace the fuel pump.

CHECK HARNESS BETWEEN FUEL PUMP AND FUEL PUMP RELAY CONNECTOR. Measure the resistance of harness between fuel pump and fuel pump relay connector. Connector & terminal (R58) No. 5 — Chassis ground: CHECK FUEL PUMP RELAY. 1) Remove the fuel pump relay. 2) Connect the battery to fuel pump relay terminals No. 17 and No. 19. 3) Measure the resistance between terminals of fuel pump relay. Terminals No. 20 — No. 21: CHECK HARNESS BETWEEN ECM AND FUEL PUMP RELAY CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and fuel pump relay connector. Connector & terminal (B136) No. 33 — (B220) No. 19: CHECK POWER SUPPLY OF FUEL PUMP RELAY. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel pump relay connector and chassis ground. Connector & terminal (B220) No. 17 (+) — Chassis ground (–): (B220) No. 21 (+) — Chassis ground (–):

Go to step 6.

Is the resistance 1 MΩ or more?

Go to step 5.

Is the resistance less than 1 Ω? Go to step 7.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between fuel pump connector and chassis grounding terminal • Poor contact of coupling connector Go to step 4.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between fuel pump connector and fuel pump relay connector • Poor contact of coupling connector Repair the short circuit to ground in harness between fuel pump connector and fuel pump relay connector. Replace the fuel pump relay.

Is the resistance less than 1 Ω? Go to step 8.

Repair the open circuit of harness between ECM and fuel pump relay connector.

Is the voltage 10 V or more?

Repair the open or ground short circuit of harness of power supply circuit.

EN(H4SO)(diag)-76

Repair the poor contact of ECM connector.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

F: FUEL INJECTOR CIRCUIT CAUTION: • Check or repair only faulty parts. • After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

MAIN RELAY M/B No. 16 4 3 2 1

E

B220

13 45

12 44

11

ECM

43

42

48

10

B134

B21 E2

FUEL INJECTOR No. 1

E5

E16

E6

E17

1 2

FUEL INJECTOR No. 2

FUEL INJECTOR No. 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 43 48

36 49

37 44 50

38 45 51

1

2

FUEL INJECTOR No. 4

B134

B21

34 42

E17

1

2

E6

1

2

E16

1

2

E5

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B220

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

41 47 54

EN-07705

1

Step Check CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump emit operTOR. ating sound? While cranking the engine, check each fuel injector emits operating sound. Use a sound scope or attach a screwdriver to the injector to listen to sounds for this check.

EN(H4SO)(diag)-77

Yes No Check the fuel Go to step 2. pressure.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

2

Step Check CHECK POWER SUPPLY TO EACH FUEL IN- Is the voltage 10 V or more? JECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector. 3) Turn the ignition switch to ON. 4) Measure the voltage between fuel injector connector and the engine ground. Connector & terminal #1 (E5) No. 2 (+) — Engine ground (–): #2 (E16) No. 2 (+) — Engine ground (–): #3 (E6) No. 2 (+) — Engine ground (–): #4 (E17) No. 2 (+) — Engine ground (–):

Yes Go to step 3.

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FUEL INJECTOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and fuel injector connector. Connector & terminal #1 (B134) No. 10 — (E5) No. 1: #2 (B134) No. 11 — (E16) No. 1: #3 (B134) No. 12 — (E6) No. 1: #4 (B134) No. 13 — (E17) No. 1:

4

CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal #1 (B134) No. 10 — Chassis ground: #2 (B134) No. 11 — Chassis ground: #3 (B134) No. 12 — Chassis ground: #4 (B134) No. 13 — Chassis ground: CHECK EACH FUEL INJECTOR. Measure the resistance between each fuel injector terminals. Terminals No. 1 — No. 2: CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

5

6

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between main relay connector and fuel injector connector • Poor contact of main relay connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel injector connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and fuel injector connector.

Is the resistance 1 MΩ or more?

Go to step 5.

Is the resistance 5 — 20 Ω?

Go to step 6.

Replace the faulty fuel injector.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

Inspection using “General Diagnostic Table”

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

17.List of Diagnostic Trouble Code (DTC) A: LIST DTC P0026

Item Intake Valve Control Solenoid Circuit Range/Performance (Bank 1)

P0028

Intake Valve Control Solenoid Circuit Range/Performance (Bank 2)

P0030

HO2S Heater Control Circuit (Bank 1 Sensor 1)

P0031

HO2S Heater Control Circuit Low (Bank 1 Sensor 1)

P0032

HO2S Heater Control Circuit High (Bank 1 Sensor 1)

P0037

HO2S Heater Control Circuit Low (Bank 1 Sensor 2)

P0038

HO2S Heater Control Circuit High (Bank 1 Sensor 2)

P0068

MAP/MAF - Throttle Position Correlation

P0076

Intake Valve Control Solenoid Circuit Low (Bank 1)

P0077

Intake Valve Control Solenoid Circuit High (Bank 1)

P0082

Intake Valve Control Solenoid Circuit Low (Bank 2)

P0083

Intake Valve Control Solenoid Circuit High (Bank 2)

P0101

Mass or Volume Air Flow Circuit Range/Performance

P0102

Mass or Volume Air Flow Circuit Low Input

P0103

Mass or Volume Air Flow Circuit High Input

P0107

Manifold Absolute Pressure/Barometric Pressure Circuit Low Input

P0108

Manifold Absolute Pressure/Barometric Pressure Circuit High Input

Index











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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0111

Item Intake Air Temperature Sensor 1 Circuit Range/Performance

P0112

Intake Air Temperature Sensor 1 Circuit Low

P0113

Intake Air Temperature Sensor 1 Circuit High

P0117

Engine Coolant Temperature Circuit Low

P0118

Engine Coolant Temperature Circuit High

P0122

Throttle/Pedal Position Sensor/Switch “A” Circuit Low

P0123

Throttle/Pedal Position Sensor/Switch “A” Circuit High

P0125

Insufficient Coolant Temperature for Closed Loop Fuel Control

P0126

Insufficient Engine Coolant Temperature for Stable Operation

P0128

Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature)

P0131

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)

P0132

O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)

P0133

O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)

P0134

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)

P0137

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)

P0138

O2 Sensor Circuit High Voltage (Bank 1 Sensor 2)

P0139

O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)

P0140

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)

Index













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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0141

P0171 P0172 P0181

P0182

P0183

P0196

P0197 P0198 P0222

P0223

P0301 P0302 P0303 P0304 P0327

P0328

P0335

P0336

P0340

P0341

Item O2 Sensor Heater Circuit (Bank1 Sensor2)

Index

System Too Lean (Bank 1)

System Too Rich (Bank 1)

Fuel Temperature Sensor “A” Circuit

Fuel Temperature Sensor “A” Circuit

Fuel Temperature Sensor “A” Circuit

Engine Oil Temperature Sensor Cir Engine Oil Temperature Sensor Low

Engine Oil Temperature Sensor High Throttle/Pedal Position Sensor/Switch Throttle/Pedal Position Sensor/Switch Cylinder 1 Misfire Detected

Cylinder 2 Misfire Detected

Cylinder 3 Misfire Detected

Cylinder 4 Misfire Detected

Knock Sensor 1 Circuit Low (Bank 1

Knock Sensor 1 Circuit High (Bank 1 Crankshaft Position Sensor “A” Circuit Crankshaft Position Sensor “A” Circuit Camshaft Position Sensor “A” Circuit Camshaft Position Sensor “A” Circuit

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0400

Item Exhaust Gas Recirculation Flow

P0420

Catalyst System Efficiency Below Threshold (Bank 1)

P0442

Evaporative Emission Control System Leak Detected (Small Leak)

P0447

Evaporative Emission Control System Vent Control Circuit Open

P0448

Evaporative Emission Control System Vent Control Circuit Shorted

P0451

Evaporative Emission Control System Pressure Sensor

P0452

Evaporative Emission Control System Pressure Sensor Low Input

P0453

Evaporative Emission Control System Pressure Sensor High Input

P0456

Evaporative Emission Control System Leak Detected (Very Small Leak)

P0457

Evaporative Emission Control System Leak Detected (Fuel Cap Loose/ Off)

P0458

Evaporative Emission System Purge Control Valve Circuit Low

P0459

Evaporative Emission System Purge Control Valve Circuit High

P0461

Fuel Level Sensor “A” Circuit Range/ Performance

P0462

Fuel Level Sensor “A” Circuit Low

P0463

Fuel Level Sensor “A” Circuit High

P0464

Fuel Level Sensor Circuit Intermittent

P0500

Vehicle Speed Sensor “A”

P0506

Idle Air Control System RPM Lower Than Expected

P0507

Idle Air Control System RPM Higher Than Expected

P0512

Starter Request Circuit

P0513

Incorrect Immobilizer Key

Index















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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0604

Item Internal Control Module Random Access Memory (RAM) Error

P0605

Internal Control Module Read Only Memory (ROM) Error

P0607

Throttle Control System Circuit Range/Performance

P0638

Throttle Actuator Control Range/Performance (Bank 1)

P0700

Transmission Control System (MIL Request)

P0851

Park/Neutral Switch Input Circuit Low (AT Model)

P0851

Neutral Switch Input Circuit Low (MT Model)

P0852

Park/Neutral Switch Input Circuit High (AT Model)

P0852

Neutral Switch Input Circuit High (MT Model)

P1152

O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1)

P1153

O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1)

P1160

Return Spring Failure

P1443

Vent Control Solenoid Valve Function Problem

P1492

EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input)

P1493

EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input)

P1494

EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input)

P1495

EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input)

P1496

EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input)

P1497

EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input)

Index













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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P1498

Item EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input)

P1499

EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input)

P1518

Starter Switch Circuit Low Input

P1560

Back-Up Voltage Circuit Malfunction

P1570

Antenna

P1571

Reference Code Incompatibility

P1572

IMM Circuit Failure

P1574

Key Communication Failure

P1576

EGI Control Module EEPROM

P1577

IMM Control Module EEPROM

P1578

Meter Failure

P1602

Control Module Programming Error

P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

P2101

Throttle Actuator Control Motor Circuit Range/Performance

P2102

Throttle Actuator Control Motor Circuit Low

P2103

Throttle Actuator Control Motor Circuit High

P2109

Throttle/Pedal Position Sensor “A” Minimum Stop Performance

P2122

Throttle/Pedal Position Sensor/Switch “D” Circuit Low Input

P2123

Throttle/Pedal Position Sensor/Switch “D” Circuit High Input

P2127

Throttle/Pedal Position Sensor/Switch “E” Circuit Low Input

Index















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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P2128

P2135

P2138

P2227

P2228 P2229 U0073 U0101 U0122 U0140 U0402 U0416 U0422

Item Throttle/Pedal Position Sensor/Switch “E” Circuit High Input

Index

Throttle/Pedal Position Sensor/Switch Throttle/Pedal Position Sensor/Switch Atmospheric Pressure Sensor Range/ Barometric Pressure Circuit Low

Barometric Pressure Circuit High

CAN Failure, Bus ‘OFF’ Detection

CAN (TCU) Data not Loaded

CAN (VDC) Data not Loaded

CAN (BCU) Data not Loaded

CAN (TCU) Data Abnormal

CAN (VDC) Data Abnormal

CAN (BCU) Data Abnormal

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

18.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B137 ECM

14

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B137

21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31 B21 E2

E71

VVL DIAGNOSIS OIL PRESSURE SWITCH RH

EN-07708

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH RH CONNECTOR. 1) Warm up the engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from the ECM and variable valve lift diagnosis oil pressure switch RH. 4) Measure the resistance of harness between ECM and variable valve lift diagnosis oil pressure switch RH connector. Connector & terminal (B137) No. 14 — (E71) No. 1: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH RH CONNECTOR. Measure the resistance between the variable valve lift diagnosis oil pressure switch RH connector and engine ground. Connector & terminal (E71) No. 1 — Engine ground: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH RH CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between the variable valve lift diagnosis oil pressure switch RH connector and engine ground. Connector & terminal (E71) No. 1 (+) — Engine ground (–): CHECK DTC. 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedures, refer to “Clear Memory Mode”.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and variable valve lift diagnosis oil pressure switch RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and variable valve lift diagnosis oil pressure switch RH connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Is the voltage 10 V or more?

Repair the short Go to step 4. circuit to power supply in harness between ECM and variable valve lift diagnosis oil pressure switch RH connector.

Is DTC displayed?

Replace the oil End. switching solenoid valve RH. After replacement, go to the next step. Go to step 5. Check for oil rout- End. ing.

CHECK DTC. Is DTC displayed? 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedures, refer to “Clear Memory Mode”.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

B: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B137 ECM

13

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B137

22

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31 B21 E2

E72

VVL DIAGNOSIS OIL PRESSURE SWITCH LH

EN-07709

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH LH CONNECTOR. 1) Warm up the engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from the ECM and variable valve lift diagnosis oil pressure switch LH. 4) Measure the resistance of harness between ECM and variable valve lift diagnosis oil pressure switch LH connector. Connector & terminal (B137) No. 13 — (E72) No. 1: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH LH CONNECTOR. Measure the resistance between the variable valve lift diagnosis oil pressure switch LH connector and engine ground. Connector & terminal (E72) No. 1 — Engine ground: CHECK HARNESS BETWEEN ECM AND VARIABLE VALVE LIFT DIAGNOSIS OIL PRESSURE SWITCH LH CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between the variable valve lift diagnosis oil pressure switch LH connector and engine ground. Connector & terminal (E72) No. 1 (+) — Engine ground (–): CHECK DTC. 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedures, refer to “Clear Memory Mode”.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and variable valve lift diagnosis oil pressure switch LH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and variable valve lift diagnosis oil pressure switch LH connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Is the voltage 10 V or more?

Repair the short Go to step 4. circuit to power supply in harness between ECM and variable valve lift diagnosis oil pressure switch LH connector.

Is DTC displayed?

Replace the oil End. switching solenoid valve LH. After replacement, go to the next step. Go to step 5. Check for oil rout- End. ing.

CHECK DTC. Is DTC displayed? 1) Perform the Clear Memory Mode. 2) After idling the engine, check the DTC. NOTE: For detailed procedures, refer to “Clear Memory Mode”.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12

10

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

11

5 7 8 6

1 3 4 2

50

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8

4 3

B21 B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

D3

D: B137

37

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07782

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Start and warm up the engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 4) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 5 — (E24) No. 3: (B136) No. 6 — (E24) No. 3: (B136) No. 18 — (E24) No. 2: (B136) No. 19 — (E24) No. 1: Is the resistance 2 — 3 Ω? Go to step 3. CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 3 — No. 4:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector

Replace the front oxygen (A/F) sensor. CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact of ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

D: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12

10

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

11

5 7 8 6

1 3 4 2

50

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8

4 3

B21 B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

D3

D: B137

37

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07782

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY TO FRONT OXY- Is the voltage 10 V or more? GEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between front oxygen (A/F) sensor connector and engine ground. Connector & terminal (E24) No. 4 (+) — Engine ground (–):

Yes Go to step 2.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 5 — (E24) No. 3: (B136) No. 6 — (E24) No. 3:

3

CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

Is the resistance less than 5 Ω? Go to step 4.

4

CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 3 — No. 4:

Is the resistance 2 — 3 Ω?

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Repair the poor contact of ECM connector.

No Repair the power supply line. NOTE: In this case, repair the following item: • Open circuit in harness between A/F, oxygen sensor relay connector and front oxygen (A/F) sensor connector • Poor contact of A/F, oxygen sensor relay connector • Poor contact of coupling connector • Fault of A/F, oxygen sensor relay Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Replace the front oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

E: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12

10

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

11

5 7 8 6

1 3 4 2

50

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8

4 3

B21 B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

D3

D: B137

37

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07782

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 5 (+) — Chassis ground (–): (B136) No. 6 (+) — Chassis ground (–): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? 1) Disconnect the connector from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

EN(H4SO)(diag)-95

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector.

Repair the poor contact of ECM connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

F: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

A/F, OXYGEN SENSOR RELAY

B220

M/B No. 15 12

B21

E2

5 7 8 6

17 18 20 21 19

13 15 16 14

9 11 12 10

2

10

1 3 4 2

50

11

9

E

REAR OXYGEN SENSOR

B220

E25

B503

E25

1 3

3

4

1

1 2 3 4 5 6 7 8 2 4

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1

19

53

E2 B21

E

34 42

35 43 48

C20 C9

A29

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

A: B134

* * B6

36

1 8 9 18 19 28 29

B503

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

A: B134

B: B135 B: B135 ECM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

C: B136

D1 34

A4

A6

A3 35

40

36

37

D3

D: B137

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

*

: TERMINAL No. OPTIONAL ARRANGEMENT

EN(H4SO)(diag)-96

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07783

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY TO REAR OXYIs the voltage 10 V or more? GEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and engine ground. Connector & terminal (E25) No. 2 (+) — Engine ground (–):

Yes Go to step 2.

2

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between the ECM and oxygen sensor connector. Connector & terminal (B135) No. 6 — (E25) No. 1:

Is the resistance less than 1 Ω? Go to step 3.

3

CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

Is the resistance less than 5 Ω? Go to step 4.

4

CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor connector terminals. Terminals No. 2 — No. 1:

Is the resistance 5 — 7 Ω?

EN(H4SO)(diag)-97

Repair the poor contact of ECM connector.

No Repair the power supply line. NOTE: In this case, repair the following item: • Open circuit in harness between A/F, oxygen sensor relay connector and rear oxygen sensor connector • Poor contact of A/F, oxygen sensor relay connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Replace the rear oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

G: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

A/F, OXYGEN SENSOR RELAY

B220

M/B No. 15 12

B21

E2

5 7 8 6

17 18 20 21 19

13 15 16 14

9 11 12 10

2

10

1 3 4 2

50

11

9

E

REAR OXYGEN SENSOR

B220

E25

B503

E25

1 3

3

4

1

1 2 3 4 5 6 7 8 2 4

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1

19

53

E2 B21

E

34 42

35 43 48

C20 C9

A29

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

A: B134

* * B6

36

1 8 9 18 19 28 29

B503

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

A: B134

B: B135 B: B135 ECM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

C: B136

D1 34

A4

A6

A3 35

40

36

37

D3

D: B137

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1

E

Step CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 6 (+) — Chassis ground (–):

*

: TERMINAL No. OPTIONAL ARRANGEMENT

Check Is the voltage 10 V or more?

EN(H4SO)(diag)-98

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07783

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and rear oxygen sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check Yes CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? Repair the poor 1) Disconnect the connector from ECM. contact of ECM 2) Measure the resistance between ECM and connector. chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

EN(H4SO)(diag)-99

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

H: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MANIFOLD ABSOLUTE PRESSURE SENSOR

E21

2 1 3

1 2 3 E21

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19 7 20

E2 B21

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B21

A29 D20 A19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

A: B134

ECM

35 43 48

D: B137

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07628

1

Step CHECK AIR INTAKE SYSTEM.

Check Are there holes, loose bolts or disconnection of hose on air intake system?

EN(H4SO)(diag)-100

Yes Repair the air intake system.

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

4

Step CHECK MANIFOLD ABSOLUTE PRESSURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) For CVT models, set the select lever to “P” range or “N” range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of intake manifold pressure sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the “General Scan Tool Instruction Manual”. CHECK THROTTLE OPENING ANGLE. Read the data of throttle position signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the “General Scan Tool Instruction Manual”. CHECK THROTTLE OPENING ANGLE.

Check Yes Is the measured value 73.3 — Go to step 3. 106.6 kPa (550 — 800 mmHg, 21.65 — 31.50 inHg) when the ignition is turned ON, and 20.0 — 46.7 kPa (150 — 350 mmHg, 5.91 — 13.78 inHg) during idling?

No Replace the manifold absolute pressure sensor.

Is the measured value less than Go to step 4. 5% when throttle is fully closed?

Replace the electronic throttle control.

Is the measured value 85% or more when throttle is fully open?

Replace the electronic throttle control.

EN(H4SO)(diag)-101

Replace the manifold absolute pressure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

I:

DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)

DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 ECM

15

7

B134 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

24

23

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B21

34 42

E2

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

E69

1 2 2

1

E69

OIL SWITCHING SOLENOID VALVE RH

EN-07625

EN(H4SO)(diag)-102

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. SWITCHING SOLENOID VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve RH. 3) Measure the resistance of harness between ECM and oil switching solenoid valve RH. Connector & terminal (B134) No. 7 — (E69) No. 1: (B134) No. 15 — (E69) No. 2:

CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or SWITCHING SOLENOID VALVE RH CONmore? NECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 7 — Chassis ground: (B134) No. 15 — Chassis ground: CHECK OIL SWITCHING SOLENOID VALVE Is the resistance 6 — 12 Ω? RH. Measure the resistance between oil switching solenoid valve RH terminals. Terminals No. 1 — No. 2:

EN(H4SO)(diag)-103

Go to step 3.

Repair the poor contact of ECM and oil switching solenoid valve RH connector.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil switching solenoid valve RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil switching solenoid valve RH connector. Replace the oil switching solenoid valve RH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

J: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 ECM

15

7

B134 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

24

23

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B21

34 42

E2

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

E69

1 2 2

1

E69

OIL SWITCHING SOLENOID VALVE RH

EN-07625

EN(H4SO)(diag)-104

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. SWITCHING SOLENOID VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve RH. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 7 (+) — Chassis ground (–): (B134) No. 15 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 3. SWITCHING SOLENOID VALVE RH CONNECTOR. Measure the resistance of harness between ECM and oil switching solenoid valve RH connector. Connector & terminal (B134) No. 7 — (E69) No. 1: (B134) No. 15 — (E69) No. 2:

CHECK OIL SWITCHING SOLENOID VALVE Is the resistance 6 — 12 Ω? RH. Measure the resistance between oil switching solenoid valve RH terminals. Terminals No. 1 — No. 2:

EN(H4SO)(diag)-105

No Repair the short circuit to power supply in harness between ECM and oil switching solenoid valve RH connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil switching solenoid valve RH connector • Poor contact of coupling connector Repair the poor Replace the oil contact of ECM switching solenoid and oil switching valve RH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

K: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 ECM

14

5

B134 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

28

27

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B21

34 42

E2

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

E70

1 2 2

1

E70

OIL SWITCHING SOLENOID VALVE LH

EN-07626

EN(H4SO)(diag)-106

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. SWITCHING SOLENOID VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve LH. 3) Measure the resistance between ECM and oil switching solenoid valve LH. Connector & terminal (B134) No. 5 — (E70) No. 1: (B134) No. 14 — (E70) No. 2:

CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or SWITCHING SOLENOID VALVE LH CONmore? NECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 — Chassis ground: (B134) No. 14 — Chassis ground: CHECK OIL SWITCHING SOLENOID VALVE Is the resistance 6 — 12 Ω? LH. Measure the resistance between oil switching solenoid valve LH terminals. Terminals No. 1 — No. 2:

EN(H4SO)(diag)-107

Go to step 3.

Repair the poor contact of ECM and oil switching solenoid valve LH connector.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil switching solenoid valve LH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil switching solenoid valve LH connector. Replace the oil switching solenoid valve LH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

L: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 ECM

14

5

B134 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

28

27

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B21

34 42

E2

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

E70

1 2 2

1

E70

OIL SWITCHING SOLENOID VALVE LH

EN-07626

EN(H4SO)(diag)-108

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. SWITCHING SOLENOID VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and oil switching solenoid valve LH. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 5 (+) — Chassis ground (–): (B134) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 3. SWITCHING SOLENOID VALVE LH CONNECTOR. Measure the resistance between ECM and oil switching solenoid valve LH connector. Connector & terminal (B134) No. 5 — (E70) No. 1: (B134) No. 14 — (E70) No. 2:

CHECK OIL SWITCHING SOLENOID VALVE Is the resistance 6 — 12 Ω? LH. Measure the resistance between oil switching solenoid valve LH terminals. Terminals No. 1 — No. 2:

EN(H4SO)(diag)-109

Repair the poor contact of ECM and oil switching solenoid valve LH connector.

No Repair the short circuit to power supply in harness between ECM and oil switching solenoid valve LH connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil switching solenoid valve LH connector • Poor contact of coupling connector Replace the oil switching solenoid valve LH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

M: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

4 C11

1

5 C22

2

B3

* *

C31

: TERMINAL No. OPTIONAL ARRANGEMENT

C10

*

B30

B83

ECM B: B135

B3 1 2 3 4 5

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C: B136

C B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

B220

B83 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

EN-07784

EN(H4SO)(diag)-110

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H4SO)(diag)-111

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the mass air flow and intake air temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

N: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

4 C11

1

5 C22

2

B3

* *

C31

: TERMINAL No. OPTIONAL ARRANGEMENT

C10

*

B30

B83

ECM B: B135

B3 1 2 3 4 5

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

C: B136

C B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

B220

B83 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

EN-07784

EN(H4SO)(diag)-112

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the voltage less than 0.2 V? Go to step 2. 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK POWER SUPPLY OF MASS AIR Is the voltage 10 V or more? FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from mass air flow and intake air temperature sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 3 (+) — Engine ground (–):

3

CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and the mass air flow and intake air temperature sensor connector. Connector & terminal (B136) No. 22 — (B3) No. 5: CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 22 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM and mass air flow and intake air temperature sensor connector.

4

5

Go to step 3.

Is the resistance less than 1 Ω? Go to step 4.

Is the resistance 1 MΩ or more?

Is there poor contact of the ECM or the mass air flow and intake air temperature sensor connector?

EN(H4SO)(diag)-113

Go to step 5.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between main relay and mass air flow and intake air temperature sensor connector • Poor contact of main relay connector Repair the open circuit of harness between the ECM and mass air flow and intake air temperature sensor connector.

Repair the ground short circuit of harness between ECM and mass air flow and intake air temperature sensor connector. Repair the poor Replace the mass contact of ECM or air flow and intake mass air flow and air temperature intake air tempera- sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

O: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

4 C11

1

5 C22

2

B3

* *

C31

: TERMINAL No. OPTIONAL ARRANGEMENT

C10

*

B30

B83

ECM B: B135

B3 1 2 3 4 5

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

C: B136

C B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

B220

B83 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

EN-07784

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check CHECK CURRENT DATA. Is the voltage 5 V or more? 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Yes Go to step 2.

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from mass air flow and intake air temperature sensor. 3) Start the engine. 4) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 4 — Engine ground:

Repair the short circuit of harness to power supply between ECM and mass air flow and intake air temperature sensor connector.

CHECK FOR POOR CONTACT. Check for poor contact of mass air flow and intake air temperature sensor connector.

Go to step 4.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and mass air flow and intake air temperature sensor connector. • Poor contact of ECM connector Is there poor contact in the Repair any poor Replace the mass mass air flow and intake air contact of the air flow and intake temperature sensor connector? mass air flow and air temperature intake air tempera- sensor.

EN(H4SO)(diag)-115

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

P: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MANIFOLD ABSOLUTE PRESSURE SENSOR

E21

2 1 3

1 2 3 E21

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19 7 20

E2 B21

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B21

A29 D20 A19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

A: B134

ECM

35 43 48

D: B137

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the measured value less than Go to step 2. 1) Start the engine. 13.3 kPa (100 mmHg, 3.94 2) Read the data of intake manifold absolute inHg)? pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK POWER SUPPLY OF MANIFOLD ABSOLUTE PRESSURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 3 (+) — Engine ground (–):

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and manifold absolute pressure sensor connector. Connector & terminal (B137) No. 20 — (E21) No. 1:

4

CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 20 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM and manifold absolute pressure sensor connector.

5

Is the voltage 4.5 V or more?

Is the resistance 1 MΩ or more?

Go to step 3.

Go to step 5.

Is there poor contact of ECM or Repair the poor manifold absolute pressure contact of ECM or sensor connector? manifold absolute pressure sensor connector.

EN(H4SO)(diag)-117

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and manifold absolute pressure sensor connector. • Poor contact of ECM connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and manifold absolute pressure sensor connector. • Poor contact of coupling connector Repair ground short circuit of harness between ECM and manifold absolute pressure sensor connector. Replace the manifold absolute pressure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

Q: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MANIFOLD ABSOLUTE PRESSURE SENSOR

E21

2 1 3

1 2 3 E21

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19 7 20

E2 B21

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B21

A29 D20 A19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

A: B134

ECM

35 43 48

D: B137

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Go to step 2. Is the measured value 119.5 1) Start the engine. kPa (896.5 mmHg, 35.29 inHg) 2) Read the data of intake manifold absolute or more? pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Start the engine. 4) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 2 — Engine ground:

Is the measured value 119.5 Repair the short kPa (896.5 mmHg, 35.29 inHg) circuit of harness or more? to power supply between ECM and manifold absolute pressure sensor connector.

CHECK FOR POOR CONTACT. Check for poor contact of manifold absolute pressure sensor connector.

Is there poor contact of manifold absolute pressure sensor connector?

Is the resistance less than 5 Ω? Go to step 4.

EN(H4SO)(diag)-119

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and manifold absolute pressure sensor connector. • Poor contact of ECM connector • Poor contact of coupling connector Repair the poor Replace the manicontact of manifold absolute presfold absolute pres- sure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

R: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

4 C11

1

5 C22

2

B3

* *

C31

: TERMINAL No. OPTIONAL ARRANGEMENT

C10

*

B30

B83

ECM B: B135

B3 1 2 3 4 5

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35

C: B136

C B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

B220

B83 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK ENGINE COOLANT TEMPERAIs the temperature 75°C TURE. (167°F) or more? 1) Start the engine and warm up completely. 2) Measure the engine coolant temperature using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H4SO)(diag)-121

Yes Replace the mass air flow and intake air temperature sensor.

No Check for DTC P0125.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

S: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

4 C11

1

5 C22

2

B3

* *

C31

: TERMINAL No. OPTIONAL ARRANGEMENT

C10

*

B30

B83

ECM B: B135

B3 1 2 3 4 5

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C: B136

C B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

B220

B83 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the intake air temperature 1) Start the engine. 120°C (248°F) or more? 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Yes Go to step 2.

CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or MASS AIR FLOW AND INTAKE AIR TEMmore? PERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and mass air flow and intake air temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 31 — Chassis ground:

Replace the mass air flow and intake air temperature sensor.

EN(H4SO)(diag)-123

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the ground short circuit of harness between ECM and mass air flow and intake air temperature sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

T: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

4 C11

1

5 C22

2

B3

* *

C31

: TERMINAL No. OPTIONAL ARRANGEMENT

C10

*

B30

B83

ECM B: B135

B3 1 2 3 4 5

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C: B136

C B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

B220

B83 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

EN-07784

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check CHECK CURRENT DATA. Is the intake air temperature 1) Start the engine. less than –40°C (–40°F)? 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK FOR POOR CONTACT. Check for poor contact of ECM and mass air flow and intake air temperature sensor connector.

Is there poor contact of the ECM or the mass air flow and intake air temperature sensor connector?

Yes Go to step 2.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the poor contact of ECM or mass air flow and intake air temperature sensor connector. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. Repair the harness MASS AIR FLOW AND INTAKE AIR TEMand connector. PERATURE SENSOR CONNECTOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connector from ECM and the following item: mass air flow and intake air temperature sensor. • Open circuit in 3) Measure the resistance of harness between harness between ECM and the mass air flow and intake air temECM and mass air perature sensor connector. flow and intake air Connector & terminal temperature sen(B136) No. 31 — (B3) No. 1: sor connector. (B135) No. 30 — (B3) No. 2: • Poor contact of joint connector CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? Repair the short Replace the mass MASS AIR FLOW AND INTAKE AIR TEMcircuit of harness air flow and intake PERATURE SENSOR CONNECTOR. to power supply air temperature 1) Connect all connectors. between ECM and sensor. (B136) No. 31 (+) — Chassis ground (–):

EN(H4SO)(diag)-125

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

U: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

ENGINE COOLANT TEMPERATURE SENSOR

E8

1

2

1 2 E8

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19

8

E2 B21 B137

D:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

B21

A29

D22

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

A : B134

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

ECM D : B137

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the temperature 150°C 1) Start the engine. (302°F) or more? 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND EN- Is the resistance 1 MΩ or GINE COOLANT TEMPERATURE SENSOR more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and engine coolant temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 22 — Chassis ground:

EN(H4SO)(diag)-127

Yes Go to step 2.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Replace the Repair short cirengine coolant cuit in harness to temperature sen- ground between sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

V: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

ENGINE COOLANT TEMPERATURE SENSOR

E8

1

2

1 2 E8

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19

8

E2 B21 B137

D:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

B21

A29

D22

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

A : B134

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

ECM D : B137

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Is the engine coolant tempera- Go to step 2. 1) Start the engine. ture less than –40°C (–40°F)? 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Check for poor contact of ECM and engine cool- engine coolant temperature contact of ECM or ant temperature sensor connector. sensor connector? engine coolant temperature sensor connector. CHECK HARNESS BETWEEN ECM AND EN- Is the resistance less than 1 Ω? Go to step 4. GINE COOLANT TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and engine coolant temperature sensor. 3) Measure the resistance of harness between ECM and engine coolant temperature sensor connector. Connector & terminal (B137) No. 22 — (E8) No. 2: (B134) No. 29 — (E8) No. 1: CHECK HARNESS BETWEEN ECM AND EN- Is the voltage 5 V or more? GINE COOLANT TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 22 (+) — Chassis ground (–):

EN(H4SO)(diag)-129

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and engine coolant temperature sensor connector • Poor contact of coupling connector Repair the short Replace the circuit of harness engine coolant to power supply temperature senbetween ECM and sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

W: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E

E57

6

4

5 1 2 3

E2

*

ELECTRONIC THROTTLE CONTROL

E

E57

B138

B21

1 2 3 4 5 6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220

34 42 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

A:

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 28 29 26 27

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Replace the electronic throttle control.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective.

EN(H4SO)(diag)-131

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

X: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E

E57

6

4

5 1 2 3

E2

*

ELECTRONIC THROTTLE CONTROL

E

E57

B138

B21

1 2 3 4 5 6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220

34 42 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

A:

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 28 29 26 27

EN-07785

EN(H4SO)(diag)-132

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 29 — (E57) No. 3:

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 3. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

3

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL CON- more? NECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18:

4

EN(H4SO)(diag)-133

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

Y: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Engine does not return to idle. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK TIRE SIZE.

2

CHECK ENGINE COOLANT. Check the following items: • Amount of engine coolant • Engine coolant freeze • Contamination of engine coolant

3

CHECK THERMOSTAT.

Check Yes Is the tire size as specified and Go to step 2. the same size as three other wheels? Is the engine coolant normal? Go to step 3.

Does the thermostat remain opened?

EN(H4SO)(diag)-134

Replace the thermostat.

No Replace the tire.

Fill or replace the engine coolant.

Replace the engine coolant temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

Z: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

ENGINE COOLANT TEMPERATURE SENSOR

E8

1

2

1 2 E8

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19

8

E2 B21 B137

D:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

B21

A29

D22

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

A : B134

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

ECM D : B137

EN-07629

EN(H4SO)(diag)-135

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. Measure the resistance between engine coolant temperature sensor terminals when the engine coolant is cold and after warmed up. Terminals No. 1 — No. 2:

Check Yes Is the resistance of engine cool- Repair the poor ant temperature sensor differ- contact of ECM ent between when engine connector. coolant is cold and after warmed up?

EN(H4SO)(diag)-136

No Replace the engine coolant temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AA:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Thermostat remains open. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK ENGINE COOLANT.

Check Is the engine coolant amount normal?

CHECK RADIATOR FAN. 1) Start the engine. 2) Check the radiator fan operation.

Does the radiator fan continuously rotate for 3 minutes or more during idling?

EN(H4SO)(diag)-137

Yes Go to step 2.

No Refill the engine coolant. Repair radiator fan Replace the thercircuit. and

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AB:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12

10

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

11

5 7 8 6

1 3 4 2

50

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8 B21

4 3

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

37

D3

D: B137

2 10 20 30

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07782

1

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H4SO)(diag)-138

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 18 — Chassis ground: (B136) No. 19 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of the front oxygen (A/F) sensor connector.

Check Is the resistance 1 MΩ or more?

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

Is there poor contact of front oxygen (A/F) sensor connector?

Repair the poor contact of front oxygen (A/F) sensor connector.

Replace the front oxygen (A/F) sensor.

EN(H4SO)(diag)-139

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AC:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12

10

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

11

5 7 8 6

1 3 4 2

50

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8 B21

4 3

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

37

D3

D: B137

2 10 20 30

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07782

1

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H4SO)(diag)-140

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 8 V or more? FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 18 (+) — Chassis ground (–): (B136) No. 19 (+) — Chassis ground (–):

EN(H4SO)(diag)-141

Yes Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector.

No Replace the front oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AD:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12

10

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

11

5 7 8 6

1 3 4 2

50

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8

4 3

B21 B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

D3

D: B137

37

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07782

EN(H4SO)(diag)-142

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust system? NOTE: Check the following items. • Loose installation of front portion of exhaust pipe onto cylinder heads • Loose connection between front exhaust pipe and front catalytic converter • Damage of exhaust pipe resulting in a hole

EN(H4SO)(diag)-143

Yes No Repair the exhaust Replace the front system. oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AE:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

10

5 7 8 6

1 3 4 2

50

11

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8

4 3

B21 B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

D3

D: B137

37

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07782

EN(H4SO)(diag)-144

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 18 — (E24) No. 2: (B136) No. 19 — (E24) No. 1:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact of ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor.

EN(H4SO)(diag)-145

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AF:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

A/F, OXYGEN SENSOR RELAY

B220

M/B No. 15 12

B21

E2

5 7 8 6

17 18 20 21 19

13 15 16 14

9 11 12 10

2

10

1 3 4 2

50

11

9

E

REAR OXYGEN SENSOR

B220

E25

B503

E25

1 3

3

4

1

1 2 3 4 5 6 7 8 2 4

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1

19

53

E2 B21

E

34 42

35 43 48

C20 C9

A29

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

A: B134

* * B6

36

1 8 9 18 19 28 29

B503

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

A: B134

B: B135 B: B135 ECM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

C: B136

D1 34

A4

A6

A3 35

40

36

37

D3

D: B137

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

*

: TERMINAL No. OPTIONAL ARRANGEMENT

EN(H4SO)(diag)-146

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07783

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 490 mV or more? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B134) No. 29 — (E25) No. 4:

4

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

5

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Loose part and improper installation between front oxygen (A/F) sensor and rear oxygen sensor

Is the voltage 0.2 — 0.5 V?

EN(H4SO)(diag)-147

No Go to step 2.

Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of rear oxygen sensor connector • Poor contact of ECM connector Repair or replace Replace the rear faulty parts. oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AG:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

A/F, OXYGEN SENSOR RELAY

B220

M/B No. 15 12

B21

E2

5 7 8 6

17 18 20 21 19

13 15 16 14

9 11 12 10

2

10

1 3 4 2

50

11

9

E

REAR OXYGEN SENSOR

B220

E25

B503

E25

1 3

3

4

1

1 2 3 4 5 6 7 8 2 4

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1

19

53

E2 B21

E

34 42

35 43 48

C20 C9

A29

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

A: B134

* * B6

36

1 8 9 18 19 28 29

B503

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

A: B134

B: B135 B: B135 ECM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

C: B136

D1 34

A4

A6

A3 35

40

36

37

D3

D: B137

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

*

: TERMINAL No. OPTIONAL ARRANGEMENT

EN(H4SO)(diag)-148

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07783

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 250 mV or less? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B134) No. 29 — (E25) No. 4:

4

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

5

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Loose part and improper installation between front oxygen (A/F) sensor and rear oxygen sensor

Is the voltage 0.2 — 0.5 V?

EN(H4SO)(diag)-149

No Go to step 2.

Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of rear oxygen sensor connector • Poor contact of ECM connector Repair or replace Replace the rear faulty parts. oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AH:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

A/F, OXYGEN SENSOR RELAY

B220

M/B No. 15 12

B21

E2

5 7 8 6

17 18 20 21 19

13 15 16 14

9 11 12 10

2

10

1 3 4 2

50

11

9

E

REAR OXYGEN SENSOR

B220

E25

B503

E25

1 3

3

4

1

1 2 3 4 5 6 7 8 2 4

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1

19

53

E2 B21

E

34 42

35 43 48

C20 C9

A29

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

A: B134

* * B6

36

1 8 9 18 19 28 29

B503

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

A: B134

B: B135 B: B135 ECM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

C: B136

D1 34

A4

A6

A3 35

40

36

37

D3

D: B137

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

*

: TERMINAL No. OPTIONAL ARRANGEMENT

EN(H4SO)(diag)-150

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07783

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3:

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. Measure the resistance between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 — Chassis ground: CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor terminals. Terminals No. 3 — No. 4

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Is the resistance 1 MΩ or Go to step 3. Repair the ground more? short circuit of harness between ECM and rear oxygen sensor connector. Is the resistance less than 1 Ω? Replace the rear Even if DTC is oxygen sensor. detected, the cir duce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

EN(H4SO)(diag)-151

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AI: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

A/F, OXYGEN SENSOR RELAY

B220

M/B No. 15 12

B21

E2

5 7 8 6

17 18 20 21 19

13 15 16 14

9 11 12 10

2

10

1 3 4 2

50

11

9

E

REAR OXYGEN SENSOR

B220

E25

B503

E25

1 3

3

4

1

1 2 3 4 5 6 7 8 2 4

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1

19

53

E2 B21

E

34 42

35 43 48

C20 C9

A29

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

A: B134

* * B6

36

1 8 9 18 19 28 29

B503

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

A: B134

B: B135 B: B135 ECM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35

C: B136

D1 34

A4

A6

A3 35

40

36

37

D3

D: B137

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

*

: TERMINAL No. OPTIONAL ARRANGEMENT

EN(H4SO)(diag)-152

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN-07783

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B134) No. 29 — (E25) No. 4:

Check Yes Is the voltage 490 mV or more? Go to step 6.

No Go to step 2.

Is the voltage 250 mV or less? Go to step 6.

Go to step 3.

Has water entered the connec- Completely tor? remove any water inside. Is the resistance less than 1 Ω? Go to step 5.

Go to step 4.

EN(H4SO)(diag)-153

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

5

6

Step CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Check Is the voltage 0.2 — 0.5 V?

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Loose part and improper installation between front oxygen (A/F) sensor and rear oxygen sensor

Yes Replace the rear oxygen sensor.

Repair or replace faulty parts.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of rear oxygen sensor connector • Poor contact of ECM connector Replace the rear oxygen sensor.

AJ:DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2) Refer to DTC P0037 for diagnostic procedure.

AK:DTC P0171 SYSTEM TOO LEAN (BANK 1) Refer to DTC P0172 for diagnostic procedure.

EN(H4SO)(diag)-154

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AL:DTC P0172 SYSTEM TOO RICH (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1 2

3

4

Step CHECK EXHAUST SYSTEM.

Check Are there holes or loose bolts on exhaust system? CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 339.5 — 360.5 kPa (3.5 — 3.7 kg/cm2, WARNING: 49 — 52 psi)? Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the temperature 75°C SENSOR. (167°F) or more? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H4SO)(diag)-155

Yes No Repair the exhaust Go to step 2. system. Repair the air Go to step 3. intake system. Go to step 4.

Repair the following item. Fuel pressure is too high: • Clogged fuel line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel line

Go to step 5.

Replace the engine coolant temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

5

6

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) For CVT models, set the select lever to “P” range or “N” range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 70°C (158°F). 2) For CVT models, set the select lever to “P” range or “N” range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)?

Yes Go to step 6.

Subtract ambient temperature Repair the poor from intake air temperature. Is contact of ECM the obtained value –10 — 50°C connector. (–18 — 90°F)?

EN(H4SO)(diag)-156

No Replace the mass air flow and intake air temperature sensor.

Check the mass air flow and intake air temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AM:DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

2 3

FUEL TEMPERATURE SENSOR

R58

7 11

R57 R15

3 8

R333 i155

11 5

i3 B38

* *

*

: TERMINAL No. OPTIONAL ARRANGEMENT

C23 B30

B83

B : B135 ECM

C : B136

R58

B83

1 2

1 2 3 4 5 6 7 8

3 4 5 6

i155 1 3

4 5 6 8 9 10 11

B : B135

B38

R57

2 7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07786

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H4SO)(diag)-158

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the fuel temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AN:DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

2 3

FUEL TEMPERATURE SENSOR

R58

7 11

R57 R15

3 8

R333 i155

11 5

i3 B38

* *

*

: TERMINAL No. OPTIONAL ARRANGEMENT

C23 B30

B83

B : B135 ECM

C : B136

R58

B83

1 2

1 2 3 4 5 6 7 8

3 4 5 6

i155 1 3

4 5 6 8 9 10 11

B : B135

B38

R57

2 7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07786

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the temperature 120°C 1) Start the engine. (248°F) or higher? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

Yes Go to step 2.

CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or FUEL TEMPERATURE SENSOR CONNEC- more? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and fuel temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 23 — Chassis ground:

Replace the fuel temperature sensor.

EN(H4SO)(diag)-160

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the ground short circuit of harness between ECM and fuel pump.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AO:DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

2 3

FUEL TEMPERATURE SENSOR

R58

7 11

R57 R15

3 8

R333 i155

11 5

i3 B38

* *

*

: TERMINAL No. OPTIONAL ARRANGEMENT

C23 B30

B83

B : B135 ECM

C : B136

R58

B83

1 2

1 2 3 4 5 6 7 8

3 4 5 6

i155 1 3

4 5 6 8 9 10 11

B : B135

B38

R57

2 7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07786

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK CURRENT DATA. Is the temperature less than – 1) Start the engine. 40°C (–40°F)? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

2

CHECK FOR POOR CONTACT. Is there poor contact of the Repair any poor contact between the ECM and ECM or fuel temperature senfuel temperature sensor connectors. sor connectors?

3

CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and fuel temperature sensor. 3) Measure the resistance of the harness between the ECM and fuel temperature sensor connector. Connector & terminal (B136) No. 23 — (R58) No. 2: (B135) No. 30 — (R58) No. 3:

4

CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 23 (+) — Chassis ground (–):

Yes Go to step 2.

Repair any poor contact between the ECM and fuel temperature sensor connectors. Is the resistance less than 1 Ω? Go to step 4.

Is the voltage 5 V or more?

EN(H4SO)(diag)-162

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel temperature sensor connector • Poor contact of coupling connector • Poor contact of joint connector Repair the short Replace the fuel circuit to power in temperature senthe harness sor. nector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AP:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: E75 1 2

1

2

OIL TEMPERATURE SENSOR

E75

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19

6

E2 D:

B21

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

A29

D21

B21

34 42

A: B134

ECM

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

D: B137

EN-07787

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H4SO)(diag)-164

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the oil temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AQ:DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: E75 1 2

1

2

OIL TEMPERATURE SENSOR

E75

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19

6

E2 D:

B21

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

A29

D21

B21

34 42

A: B134

ECM

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

D: B137

EN-07787

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the oil temperature 215°C 1) Start the engine. (419°F) or more? 2) Read the data of oil temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or TEMPERATURE SENSOR CONNECTOR. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and oil temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 21 — Chassis ground:

EN(H4SO)(diag)-166

Yes Go to step 2.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Replace the oil Repair the short temperature sen- circuit to ground in sor. connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AR:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: E75 1 2

1

2

OIL TEMPERATURE SENSOR

E75

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19

6

E2 D:

B21

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

A29

D21

B21

34 42

A: B134

ECM

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

D: B137

EN-07787

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Is the oil temperature less than Go to step 2. 1) Start the engine. –40°C (–40°F)? 2) Read the data of oil temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Check for poor contact of ECM and oil tempera- oil temperature sensor connec- contact of ECM or ture sensor connector. tor? oil temperature sensor connector. CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 4. TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and oil temperature sensor. 3) Measure the resistance of harness between ECM and oil temperature sensor connector. Connector & terminal (B137) No. 21 — (E75) No. 2: (B134) No. 29 — (E75) No. 1:

CHECK HARNESS BETWEEN ECM AND OIL Is the voltage 5 V or more? TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 21 (+) — Chassis ground (–):

EN(H4SO)(diag)-168

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil temperature sensor connector • Poor contact of coupling connector Repair the short Replace the oil circuit to power temperature sensupply in harness sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AS:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E

E57

6

4

5 1 2 3

E2

*

ELECTRONIC THROTTLE CONTROL

E

E57

B138

B21

1 2 3 4 5 6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220

34 42 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

A:

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 28 29 26 27

EN-07785

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 28 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 4 — Engine ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Replace the electronic throttle control.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective.

EN(H4SO)(diag)-170

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AT:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E

E57

6

4

5 1 2 3

E2

*

ELECTRONIC THROTTLE CONTROL

E

E57

B138

B21

1 2 3 4 5 6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220

34 42 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

A:

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 28 29 26 27

EN-07785

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 3. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

3

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 4 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL CON- more? NECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 28:

4

EN(H4SO)(diag)-172

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AU:DTC P0301 CYLINDER 1 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304.

AV:DTC P0302 CYLINDER 2 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304.

AW:DTC P0303 CYLINDER 3 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304.

EN(H4SO)(diag)-173

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AX:DTC P0304 CYLINDER 4 MISFIRE DETECTED DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • Immediately at fault recognition (A misfire which could damage catalyst occurs.) • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls • Improper idling • Rough driving CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

MAIN RELAY M/B No. 16 4 3 2 1

E

B220

13 45

12 44

11

ECM

43

42

48

10

B134

B21 E2

FUEL INJECTOR No. 1

E5

E16

E6

E17

1 2

FUEL INJECTOR No. 2

FUEL INJECTOR No. 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 43 48

36 49

37 44 50

38 45 51

1

2

E17

FUEL INJECTOR No. 4

B134

B21

34 42

1

2

E6

1

2

E16

1

2

E5

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B220

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

41 47 54

EN-07705

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Measure the resistance between fuel injector connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 — Engine ground: #2 (E16) No. 1 — Engine ground: #3 (E6) No. 1 — Engine ground: #4 (E17) No. 1 — Engine ground: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure the resistance of harness between ECM and fuel injector connector on faulty cylinders. Connector & terminal #1 (B134) No. 10 — (E5) No. 1: #2 (B134) No. 11 — (E16) No. 1: #3 (B134) No. 12 — (E6) No. 1: #4 (B134) No. 13 — (E17) No. 1:

Check Is the voltage 10 V or more?

Yes Go to step 6.

No Go to step 2.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the ground short circuit of harness between ECM and fuel injector connector.

Is the resistance less than 1 Ω? Go to step 4.

CHECK FUEL INJECTOR. Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK POWER SUPPLY LINE. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel injector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 2 (+) — Engine ground (–): #2 (E16) No. 2 (+) — Engine ground (–): #3 (E6) No. 2 (+) — Engine ground (–): #4 (E17) No. 2 (+) — Engine ground (–):

Is the resistance 5 — 20 Ω?

Go to step 5.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel injector connector • Poor contact of coupling connector Replace the faulty fuel injector.

Is the voltage 10 V or more?

Repair the poor contact of all connectors in fuel injector circuit.

EN(H4SO)(diag)-175

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between the main relay connector and fuel injector connector on faulty cylinders • Poor contact of coupling connector • Poor contact of main relay connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

7

8

9

10

11

12

Step CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–): CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK INSTALLATION CONDITION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR.

Check Is the voltage 10 V or more?

Yes No Repair the short Go to step 7. circuit to power in harness between ECM and fuel injector connector.

Is the resistance 5 — 20 Ω?

Replace the faulty Go to step 8. fuel injector.

Is the camshaft position sensor Tighten the cam- Go to step 9. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. Is the crank sprocket rusted or Replace the crank Go to step 10. CHECK CRANK SPROCKET. Remove the timing belt cover. CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Go to step 11. TIMING BELT. from its proper position? tion condition of Turn the crankshaft using ST, and align the timing belt. ST 499987500 CRANKSHAFT SOCKET CHECK FUEL LEVEL. Is the fuel meter indication Go to step 12. Refill the fuel so higher than the “Lower” level? that fuel meter indication is higher than the “Lower” level. After replenishing fuel, Go to step 12. CHECK STATUS OF MALFUNCTION INDIGo to step 13. Does the malfunction indicator Go to step 14. CATOR LIGHT. light illuminate or blink? 1) Clear the memory using the Subaru Select Monitor or general scan tool.

2) Start the engine, and drive the vehicle 10 minutes or more.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

13

Step CHECK CAUSE OF MISFIRE.

Check Yes Was the cause of misfire identi- Finish diagnostics fied when the engine is runoperation, if the ning? engine has no abnormality.

14

CHECK AIR INTAKE SYSTEM.

Is there any fault in air intake system?

15

CHECK MISFIRE SYMPTOM. 1) Turn the ignition switch to ON. 2) Read the DTC. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK DTC. Is DTC P0301 and P0302 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Is DTC P0303 and P0304 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Is DTC P0301 and P0303 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Is DTC P0302 and P0304 displayed on the Subaru Select Monitor or general scan tool?

16

17

18

19

No Repair the poor contact of connector. NOTE: In this case, repair the following item: • Poor contact of ignition coil connector • Poor contact of fuel injector connector on faulty cylinders • Poor contact of ECM connector • Poor contact of coupling connector Go to step 15.

Repair the air intake system. NOTE: Check the following items. • Are there air leaks or air suction caused by loose or dislocated nuts and bolts? • Are there cracks or any disconnection of hoses? Does the Subaru Select Moni- Go to step 20. Go to step 16. tor or general scan tool indicate only one DTC?

EN(H4SO)(diag)-177

Go to step 21.

Go to step 17.

Go to step 22.

Go to step 18.

Go to step 23.

Go to step 19.

Go to step 24.

Go to step 25.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

20

Step ONLY ONE CYLINDER.

Check Is there any fault in the cylinder?

21

GROUP OF #1 AND #2 CYLINDERS.

Are there any faults in #1 and #2 cylinders?

22

GROUP OF #3 AND #4 CYLINDERS.

Are there any faults in #3 and #4 cylinders?

EN(H4SO)(diag)-178

Yes Repair or replace faulty parts. NOTE: Check the following items. • Spark plug • Spark plug cord • Fuel injector • Compression ratio Repair or replace faulty parts. NOTE: • Check the following items. • Spark plug • Fuel injector • Ignition coil • Compression ratio • If any fault are not found, check the “IGNITION CONTROL SYSTEM” of #1 and #2 cylinders side.

Repair or replace faulty parts. NOTE: • Check the following items. • Spark plug • Fuel injector • Ignition coil • Compression ratio • If any fault are not found, check the “IGNITION CONTROL SYSTEM” of #3 and #4 cylinders side.

No Go to DTC P0171.

Go to DTC P0171.

Go to DTC P0171.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

23

Step GROUP OF #1 AND #3 CYLINDERS.

Check Are there any faults in #1 and #3 cylinders?

24

GROUP OF #2 AND #4 CYLINDERS.

Are there any faults in #2 and #4 cylinders?

25

CYLINDER AT RANDOM.

Is the engine idle rough?

EN(H4SO)(diag)-179

Yes Repair or replace faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio • Skipping timing belt teeth Repair or replace faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio • Skipping timing belt teeth Go to DTC P0171.

No Go to DTC P0171.

Go to DTC P0171.

Repair or replace faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AY:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

KNOCK SENSOR

2

1

E14 E14

1 2

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19

16

E2 B21

E D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

A29

D2

D8

B21

34 42

A: B134

ECM

48

D: B137

36

35 43 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07632

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B137) No. 2 — (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor terminals. Terminals No. 1 — No. 2:

Check Is the resistance 600 kΩ or more?

Yes Go to step 2.

No Repair the poor contact of ECM connector.

Is the resistance 600 kΩ or more?

Replace the knock sensor.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and knock sensor connector • Poor contact of knock sensor connector • Poor contact of coupling connector

EN(H4SO)(diag)-181

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AZ:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

KNOCK SENSOR

2

1

E14 E14

1 2

B134

A: 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

19

16

E2 B21

E D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

A29

D2

D8

B21

34 42

A: B134

ECM

48

D: B137

36

35 43 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07632

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B137) No. 2 — (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor terminals. Terminals No. 1 — No. 2:

Check Yes Is the resistance less than 500 Go to step 2. kΩ?

CHECK INPUT SIGNAL OF ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 2 (+) — Chassis ground (–):

Is the voltage 2 V or more?

Is the resistance less than 500 Replace the knock kΩ? sensor.

EN(H4SO)(diag)-183

No Go to step 3.

Repair the ground short circuit of harness between ECM and knock sensor connector. NOTE: The harness between both connectors are shielded. Remove the shield and repair the short circuit of the harness. Even if DTC is Repair the poor detected, the cir- contact of ECM cuit has returned to connector. a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BA:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

CRANKSHAFT POSITION SENSOR

E10

2 1

1 2 E10

B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 28 29 30 31 26 27

B21

15 14

E2 B21

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

25 17 31

48

36

B137

ECM

EN-07639

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK INSTALLATION CONDITION OF CRANKSHAFT POSITION SENSOR.

Check Is the crankshaft position sensor installation bolt tightened securely?

CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 and 1) Turn the ignition switch to OFF. 4 kΩ? 2) Remove the crankshaft position sensor. 3) Measure the resistance between terminals of crankshaft position sensor connector. Terminals No. 1 — No. 2: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? CRANKSHAFT POSITION SENSOR CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and crankshaft position sensor connector. Connector & terminal (B137) No. 17 — (E10) No. 1: (B137) No. 25 — (E10) No. 2:

EN(H4SO)(diag)-185

Yes Go to step 2.

Go to step 3.

Repair the poor contact of ECM and crankshaft position sensor connector.

No Tighten the crankshaft position sensor installation bolt securely. Replace the crankshaft position sensor. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and crankshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BB:DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

CRANKSHAFT POSITION SENSOR

E10

2 1

1 2 E10

B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B21

15 14

E2 B21

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

25 17 31

48

36

B137

ECM

EN-07639

EN(H4SO)(diag)-186

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR. sor installation bolt tightened Turn the ignition switch to OFF. securely?

2

CHECK CRANK SPROCKET. Remove the timing belt cover.

3

CHECK INSTALLATION CONDITION OF Is the timing belt dislocated TIMING BELT. from its proper position? Turn the crankshaft, and align alignment mark on crank sprocket with alignment mark on cylinder block. ST 499987500 CRANKSHAFT SOCKET

Are crank sprocket teeth cracked or damaged?

EN(H4SO)(diag)-187

Yes Go to step 2.

No Tighten the crankshaft position sensor installation bolt securely. Replace the crank Go to step 3. sprocket. Repair the installa- Replace the cranktion condition of shaft position sentiming belt.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BC:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

CAMSHAFT POSITION SENSOR

E15

2 1

1 2 E15

B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B21

13 12

E2 B21

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

30 24 31

48

36

B137

ECM

EN-07640

EN(H4SO)(diag)-188

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and camshaft position sensor. 3) Measure the resistance of harness between ECM and camshaft position sensor connector. Connector & terminal (B137) No. 24 — (E15) No. 1: (B137) No. 30 — (E15) No. 2:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and camshaft position sensor connector • Poor contact of ECM connector • Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or Go to step 3. Repair short cirCAMSHAFT POSITION SENSOR CONNEC- more? cuit to ground in TOR. harness between Measure the resistance between camshaft ECM and camshaft position sensor connector and engine ground. position sensor Connector & terminal connector. (E15) No. 1 — Engine ground: NOTE: The harness between both connectors are shielded. Remove the shield and repair the ground short circuit of the harness circuit. CHECK INSTALLATION CONDITION OF Is the camshaft position sensor Go to step 4. Tighten the camCAMSHAFT POSITION SENSOR. installation bolt tightened shaft position sensecurely? sor installation bolt securely. Is the resistance between 1 and Repair the poor Replace the camCHECK CAMSHAFT POSITION SENSOR. 4 kΩ? contact of ECM or shaft position sen1) Remove the camshaft position sensor. camshaft position sor.

EN(H4SO)(diag)-189

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BD:DTC P0341 CAMSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

CAMSHAFT POSITION SENSOR

E15

2 1

1 2 E15

B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B21

13 12

E2 B21

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

30 24 31

48

36

B137

ECM

EN-07640

EN(H4SO)(diag)-190

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and camshaft position sensor. 3) Measure the resistance of harness between ECM and camshaft position sensor connector. Connector & terminal (B137) No. 24 — (E15) No. 1: (B137) No. 30 — (E15) No. 2:

2

CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or CAMSHAFT POSITION SENSOR CONNEC- more? TOR. Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E15) No. 1 — Engine ground:

3

CHECK INSTALLATION CONDITION OF CAMSHAFT POSITION SENSOR.

Is the camshaft position sensor Go to step 4. installation bolt tightened securely?

4

CHECK CAMSHAFT POSITION SENSOR. 1) Remove the camshaft position sensor. 2) Measure the resistance between terminals of camshaft position sensor connector. Terminals No. 1 — No. 2: CHECK CAM SPROCKET. Remove the timing belt cover.

Is the resistance between 1 and Go to step 5. 4 kΩ?

5

6

Go to step 3.

Are cam sprocket teeth cracked Replace the cam or damaged? sprocket. CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installaTIMING BELT. from its proper position? tion condition of Turn the crankshaft using the ST, and align the timing belt. ST 499987500 CRANKSHAFT SOCKET

EN(H4SO)(diag)-191

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and camshaft position sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector. NOTE: The harness between both connectors are shielded. Remove the shield and repair the ground short circuit of the harness circuit. Tighten the camshaft position sensor installation bolt securely. Replace the camshaft position sensor. Go to step 6.

Replace the camshaft position sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BE:DTC P0400 EXHAUST GAS RECIRCULATION FLOW DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Movement performance problem when engine is low speed. • Improper idling • Movement performance problem CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: E18 BATTERY

MAIN RELAY

1 2 3 4 5 6

M/B No. 16 4 3 B21 48

2 1

B220

E2

B220

5 7 8 6

9 11 12 10

13 15 16 14

5 2

1 3 4 2

EGR VALVE

B21

E

E18

17 18 20 21 19

6 3 4 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

30 25 29 26

E2

36

A30 A8 A20 A9

B21

A: B134

A: B134 1 8 9 18 19 28 29

ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1

A3

A4

A6

D3

D: B137

2 10 20 30

34

35

40

36

37

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

B21 E2

E

E EN-07788

EN(H4SO)(diag)-192

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK EGR VALVE. Remove the EGR valve.

Check Yes No Is the measured value 53.3 kPa Make sure that the Go to step 2. (400 mmHg, 15.75 inHg) or EGR valve, manimore? fold absolute pressure sensor and throttle body are installed securely.

Are there any holes, clogged lines or foreign matters in the EGR system?

EN(H4SO)(diag)-193

Repair the EGR system.

Replace the EGR valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BF:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Idle mixture is out of specifications. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

A/F, OXYGEN SENSOR RELAY

B220

M/B No. 15 12

B21

E2

5 7 8 6

17 18 20 21 19

13 15 16 14

9 11 12 10

2

10

1 3 4 2

50

11

9

E

REAR OXYGEN SENSOR

B220

E25

B503

E25

1 3

3

4

1

1 2 3 4 5 6 7 8 2 4

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1

19

53

E2 B21

E

34 42

35 43 48

C20 C9

A29

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

A: B134

* * B6

36

1 8 9 18 19 28 29

B503

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

A: B134

B: B135 B: B135 ECM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35

C: B136

D1 34

A4

A6

A3 35

40

36

37

D3

D: B137

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

*

: TERMINAL No. OPTIONAL ARRANGEMENT

EN(H4SO)(diag)-194

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN-07783

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK EXHAUST SYSTEM. Check for gas leaks or air suction caused by loose or dislocated nuts and bolts, and open hole at exhaust pipes. NOTE: Check the following positions. • Between cylinder head and front exhaust pipe • Between front exhaust pipe and front catalytic converter • Between front catalytic converter and rear catalytic converter • Loose or improperly attached front oxygen (A/F) sensor or rear oxygen sensor CHECK WAVEFORM DATA ON THE SUBARU SELECT MONITOR (WHILE DRIVING). 1) Drive at a constant speed of 80 — 112 km/h (50 — 70 MPH). 2) After 5 minutes have elapsed in the condition of step 1), use the Subaru Select Monitor while still driving to read the waveform data. • At normal condition

Check Is there any fault in exhaust system?

Yes No Repair or replace Go to step 2. the exhaust system.

Is a normal waveform displayed?

Even if DTC is Go to step 3. detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

1 REAR OXYGEN SENSOR VOLTAGE (V) 0 1.5 A/F SENSOR OUTPUT LAMBDA 1 0.5 10 sec/div

EN-06666

• At abnormal condition (numerous inversion) 1 REAR OXYGEN SENSOR VOLTAGE (V) 0 1.5 A/F SENSOR OUTPUT LAMBDA 1 0.5 10 sec/div

EN-06667

EN(H4SO)(diag)-195

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

Step Check CHECK WAVEFORM DATA ON THE SUBA- Is a normal waveform displayed? RU SELECT MONITOR (WHILE IDLING). 1) Run the engine at idle. 2) In the state of step 1), read the waveform data using the Subaru Select Monitor. • At normal condition

Yes Go to step 4.

1

No • The waveform is displayed at abnormal condition 1:Go to step 4. • The waveform is displayed at abnormal condition 2:Go to step 5.

REAR OXYGEN SENSOR VOLTAGE (V)

0 10 sec/div

EN-06668

• At abnormal condition 1 (numerous inversion) 1

REAR OXYGEN SENSOR VOLTAGE (V)

0 10 sec/div

EN-06669

• At abnormal condition 2 (noise input) 1

REAR OXYGEN SENSOR VOLTAGE (V)

0 10 sec/div

4

5

EN-06670

CHECK CATALYTIC CONVERTER.

Is the catalytic converter dam- Replace the cataaged? lytic converter.

CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside.

EN(H4SO)(diag)-196

Go to step 5.

Go to step 6.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 7. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B134) No. 29 — (E25) No. 4:

7

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Is the voltage 0.2 — 0.5 V?

8

CHECK REAR OXYGEN SENSOR SHIELD. 1) Turn the ignition switch to OFF. 2) Expose the rear oxygen sensor connector body side harness sensor shield. 3) Measure the resistance between sensor shield and chassis ground.

Is the resistance less than 1 Ω? Replace the rear oxygen sensor.

EN(H4SO)(diag)-197

Go to step 8.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: Repair the following locations. • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM and rear oxygen sensor • Poor contact of ECM connector Repair the open circuit of rear oxygen sensor harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BG:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Fuel odor • There is a hole of more than 1.0 mm (0.04 in) dia. in evaporation system or fuel tank. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1 B: B135

D: B137

ECM

E

41

48

B38

15

1

B4

D6

B220

i3

B21 E2

9

10

i54 R99

PURGE CONTROL SOLENOID VALVE

DRAIN VALVE

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

i54 1 2 3 4 5 6 7 8 9 10 11 12 13

2

1

E4

2

1

R144

D:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B220

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B137

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E4 R144 1 2

1 2

EN(H4SO)(diag)-198

EN-07789

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 1) Turn the ignition switch to OFF. securely? 2) Check the fuel filler cap. NOTE: The DTC is stored in memory if fuel filler cap is or was loose or if the cap chain has caught while tightening. CHECK FUEL FILLER CAP. Is the fuel filler cap genuine?

3

CHECK FUEL FILLER PIPE GASKET.

4

CHECK DRAIN VALVE. 1) Install the delivery (test) mode fuse. 2) Turn the ignition switch to ON. 3) Operate the drain valve using the Subaru Select Monitor. NOTE: Drain valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”. CHECK PURGE CONTROL SOLENOID VALVE. Operate the purge control solenoid valve using the Subaru Select Monitor. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK EVAPORATIVE EMISSION CONTROL SYSTEM LINE. 1) Turn the ignition switch to OFF. 2) Check the delivery (test) mode fuse is removed.

1

5

6

7

CHECK CANISTER.

8

CHECK FUEL TANK. Remove the fuel tank.

9

CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.

Yes Go to step 2.

No Tighten fuel filler cap securely.

Go to step 3.

Replace with a genuine fuel filler cap. Go to step 4.

Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe.

Does the drain valve operate? Go to step 5. Replace the drain valve.

Does the purge control solenoid valve operate?

Go to step 6.

Is there any hole of more than Repair or replace 1.0 mm (0.04 in) dia. on evapo- the evaporation ration line? line. Is the canister damaged or is Repair or replace there a hole of more than 1.0 the canister. Is the fuel tank damaged or is Repair or replace there any hole of more than 1.0 the fuel tank. Is there any hole of more than Repair or replace the hoses or pipes. 1.0 mm (0.04 in) dia., crack, clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system?

EN(H4SO)(diag)-199

Replace the purge control solenoid valve.

Go to step 7.

Go to step 8.

Go to step 9.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BH:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1 B: B135

D: B137

ECM

E

41

48

B38

15

1

B4

D6

B220

i3

B21 E2

9

10

i54 R99

PURGE CONTROL SOLENOID VALVE

DRAIN VALVE

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

i54 1 2 3 4 5 6 7 8 9 10 11 12 13

2

1

E4

2

1

R144

D:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B220

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B137

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E4 R144 1 2

1 2

EN(H4SO)(diag)-200

EN-07789

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 4 (+) — Chassis ground (–): CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is the voltage 10 V or more?

Yes Go to step 2.

No Go to step 3.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

CHECK POWER SUPPLY TO DRAIN VALVE. Measure the voltage between drain valve and chassis ground. Connector & terminal (R144) No. 1 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND DRAIN VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and drain valve. 3) Measure the resistance between the drain valve connector and chassis ground. Connector & terminal (R144) No. 2 — Chassis ground: CHECK HARNESS BETWEEN ECM AND DRAIN VALVE CONNECTOR. Measure the resistance of harness between ECM and drain valve connector. Connector & terminal (B135) No. 4 — (R144) No. 2:

Is the voltage 10 V or more?

Go to step 4.

Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary open or short circuit of harness or temporary poor contact of connector may be the cause. Repair the power supply circuit.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the ground short circuit of harness between ECM and drain valve connector.

Is the resistance less than 1 Ω? Go to step 6.

CHECK DRAIN VALVE. Measure the resistance between drain valve terminals. Terminals No. 1 — No. 2:

Is the resistance 10 — 100 Ω? Repair the poor contact of drain valve connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and drain valve connector • Poor contact of coupling connector Replace the drain valve.

EN(H4SO)(diag)-201

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BI: DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1 B: B135

D: B137

ECM

E

41

48

B38

15

1

B4

D6

B220

i3

B21 E2

9

10

i54 R99

PURGE CONTROL SOLENOID VALVE

DRAIN VALVE

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

i54 1 2 3 4 5 6 7 8 9 10 11 12 13

2

1

E4

2

1

R144

D:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B220

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B137

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E4 R144 1 2

1 2

EN(H4SO)(diag)-202

EN-07789

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? DRAIN VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and drain valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 4 (+) — Chassis ground (–): Is the resistance less than 1 Ω? CHECK DRAIN VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between drain valve terminals. Terminals No. 1 — No. 2:

EN(H4SO)(diag)-203

Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and drain valve connector.

Replace the drain valve.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BJ:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1

2

3

FUEL TANK PRESSURE SENSOR

9

R57 8

10

R47

R15

10

11

9

R333 i155

6

12

2

i3 B38

* * *

: TERMINAL No. OPTIONAL ARRANGEMENT

B30

C21

B22

B83

B : B135 C : B136

1

B83

R57

B38

1 2 3 4 5 6 7 8

i155

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 3

4 5 6 8 9 10 11

2 7

Step CHECK FUEL FILLER CAP. 1) Turn the ignition switch to OFF. 2) Open the fuel flap.

ECM

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

R47 5 6 14 15 16 25 26 27 33 34 35

1 2 3

EN-07790

Check Is the fuel filler cap tightened securely?

EN(H4SO)(diag)-204

Yes Go to step 2.

No Tighten fuel filler cap securely.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK PRESSURE VACUUM LINE. Is there any fault in pressure/ vacuum line? NOTE: Check the following items. • Disconnection, leakage and clogging of the vacuum hoses and pipes between fuel tank pressure sensor and fuel tank • Disconnection, leakage and clogging of air ventilation hoses and pipes between fuel filler pipe and fuel tank

EN(H4SO)(diag)-205

Yes Repair or replace the hoses and pipes.

No Replace the fuel tank pressure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BK:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1

2

3

FUEL TANK PRESSURE SENSOR

9

R57 8

10

R47

R15

10

11

9

R333 i155

6

12

2

i3 B38

* * *

: TERMINAL No. OPTIONAL ARRANGEMENT

B30

C21

B22

B83

B : B135 C : B136

B83

R57

B38

1 2 3 4 5 6 7 8

i155

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 3

4 5 6 8 9 10 11

2 7

ECM

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

R47 5 6 14 15 16 25 26 27 33 34 35

1 2 3

EN-07790

EN(H4SO)(diag)-206

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the measured value less than Go to step 2. 1) Turn the ignition switch to ON. –7.41 kPa (–55.6 mmHg, –2.19 2) Read the data of fuel tank pressure sensor inHg)? signal using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK FUEL TANK PRESSURE SENSOR Is the voltage 4.5 V or more? POWER SUPPLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between the fuel tank pressure sensor connector and chassis ground. Connector & terminal (R47) No. 3 (+) — Chassis ground (–):

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between the ECM and fuel tank pressure sensor connector. Connector & terminal (B136) No. 21 — (R47) No. 2:

4

CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 21 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact between the ECM and fuel tank pressure sensor connector.

5

Is the resistance 1 MΩ or more?

Go to step 3.

Go to step 5.

Is there poor contact of the Repair the poor ECM or fuel tank pressure sen- contact of the ECM sor connector? or fuel tank pressure sensor connector.

EN(H4SO)(diag)-207

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and fuel tank pressure sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and fuel tank pressure sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and fuel tank pressure sensor connector. Replace the fuel tank pressure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BL:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1

2

3

FUEL TANK PRESSURE SENSOR

9

R57 8

10

R47

R15

10

11

9

R333 i155

6

12

2

i3 B38

* * *

: TERMINAL No. OPTIONAL ARRANGEMENT

B30

C21

B22

B83

B : B135 C : B136

B83

R57

B38

1 2 3 4 5 6 7 8

i155

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 3

4 5 6 8 9 10 11

2 7

ECM

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

R47 5 6 14 15 16 25 26 27 33 34 35

1 2 3

EN-07790

EN(H4SO)(diag)-208

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Is the measured value 7.95 kPa Go to step 2. 1) Turn the ignition switch to ON. (59.6 mmHg, 2.35 inHg) or 2) Read the data of fuel tank pressure sensor more? signal using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel tank pressure sensor connector and engine ground. Connector & terminal (R47) No. 1 — Engine ground:

Is the measured value 7.95 kPa Repair the short (59.6 mmHg, 2.35 inHg) or circuit to power in more? the harness between ECM and fuel tank pressure sensor connector.

Is the resistance less than 5 Ω? Go to step 4.

Is there poor contact of fuel CHECK FOR POOR CONTACT. Check for poor contact of the fuel tank pressure tank pressure sensor connector? sensor connector.

EN(H4SO)(diag)-209

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and fuel tank pressure sensor connector • Poor contact of ECM connector • Poor contact of coupling connector • Poor contact of joint connector Replace the fuel Repair the poor contact of fuel tank tank pressure senpressure sensor sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BM:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Fuel odor • There is a hole of more than 0.5 mm (0.020 in) dia. in evaporation system or fuel tank. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1 B: B135

D: B137

ECM

E

41

48

B38

15

1

B4

D6

B220

i3

B21 E2

9

10

i54 R99

PURGE CONTROL SOLENOID VALVE

DRAIN VALVE

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

i54 1 2 3 4 5 6 7 8 9 10 11 12 13

2

1

E4

2

1

R144

D:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B220

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B137

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E4 R144 1 2

1 2

EN(H4SO)(diag)-210

EN-07789

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 1) Turn the ignition switch to OFF. securely? 2) Check the fuel filler cap. NOTE: The DTC is stored in memory if fuel filler cap is or was loose or if the cap chain has caught while tightening. CHECK FUEL FILLER CAP. Is the fuel filler cap genuine?

3

CHECK FUEL FILLER PIPE GASKET.

4

CHECK DRAIN VALVE. 1) Install the delivery (test) mode fuse. 2) Turn the ignition switch to ON. 3) Operate the drain valve using the Subaru Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK PURGE CONTROL SOLENOID VALVE. Operate the purge control solenoid valve using the Subaru Select Monitor. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK EVAPORATIVE EMISSION CONTROL SYSTEM LINE. 1) Turn the ignition switch to OFF. 2) Check the delivery (test) mode fuse is removed.

1

5

6

7

CHECK CANISTER.

8

CHECK FUEL TANK. Remove the fuel tank.

9

CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.

Yes Go to step 2.

No Tighten fuel filler cap securely.

Go to step 3.

Replace with a genuine fuel filler cap. Go to step 4.

Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe.

Does the drain valve operate? Go to step 5. Replace the drain valve.

Does the purge control solenoid valve operate?

Go to step 6.

Is there any hole of more than Repair or replace 0.5 mm (0.020 in) dia. on evap- the evaporation oration line? line. Is the canister damaged or is Repair or replace there a hole of more than 0.5 the canister. Is the fuel tank damaged or is Repair or replace there any hole of more than 0.5 the fuel tank. Is there any hole of more than Repair or replace 0.5 mm (0.020 in) dia., crack, the hoses or pipes. clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system?

EN(H4SO)(diag)-211

Replace the purge control solenoid valve.

Go to step 7.

Go to step 8.

Go to step 9.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BN:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Fuel odor • Fuel filler cap loose or lost CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1 B: B135

D: B137

ECM

E

41

48

B38

15

1

B4

D6

B220

i3

B21 E2

9

10

i54 R99

PURGE CONTROL SOLENOID VALVE

DRAIN VALVE

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

i54 1 2 3 4 5 6 7 8 9 10 11 12 13

2

1

E4

2

1

R144

D:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B220

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B137

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E4 R144 1 2

1 2

EN(H4SO)(diag)-212

EN-07789

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 1) Turn the ignition switch to OFF. securely? 2) Check the fuel filler cap. NOTE: The DTC is stored in memory if fuel filler cap is or was loose or if the cap chain has caught while tightening. CHECK FUEL FILLER CAP. Is the fuel filler cap genuine?

3

CHECK FUEL FILLER PIPE GASKET.

4

CHECK DRAIN VALVE. 1) Install the delivery (test) mode fuse. 2) Turn the ignition switch to ON. 3) Operate the drain valve using the Subaru Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK PURGE CONTROL SOLENOID VALVE. Operate the purge control solenoid valve using the Subaru Select Monitor. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK EVAPORATIVE EMISSION CONTROL SYSTEM LINE. 1) Turn the ignition switch to OFF. 2) Check the delivery (test) mode fuse is removed.

1

5

6

Yes Go to step 2.

No Tighten fuel filler cap securely.

Go to step 3.

Replace with a genuine fuel filler cap. Go to step 4.

Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe.

Does the drain valve operate? Go to step 5. Replace the drain valve.

Does the purge control solenoid valve operate?

Go to step 6.

Replace the purge control solenoid valve.

Is there any disconnection, damage or clogging on the evaporation line?

Repair or replace the evaporation line. Repair or replace the canister. Repair or replace the fuel tank. Repair or replace the hoses or pipes.

Go to step 7.

7

CHECK CANISTER.

Is the canister damaged?

8

CHECK FUEL TANK. Remove the fuel tank.

Is the fuel tank damaged?

9

CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.

Are there holes, cracks, clogging, or disconnections, misconnection of hoses or pipes in evaporative emission control system?

EN(H4SO)(diag)-213

Go to step 8.

Go to step 9.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BO:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1 B: B135

D: B137

ECM

E

41

48

B38

15

1

B4

D6

B220

i3

B21 E2

9

10

i54 R99

PURGE CONTROL SOLENOID VALVE

DRAIN VALVE

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

i54 1 2 3 4 5 6 7 8 9 10 11 12 13

2

1

E4

2

1

R144

D:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B220

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B137

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E4 R144 1 2

1 2

EN(H4SO)(diag)-214

EN-07789

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 6 (+) — Chassis ground (–): CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is the voltage 10 V or more?

Yes Go to step 2.

No Go to step 3.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

CHECK POWER SUPPLY TO PURGE CONTROL SOLENOID VALVE. Measure the voltage between purge control solenoid valve and engine ground. Connector & terminal (E4) No. 1 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Measure the resistance between the purge control solenoid valve connector and engine ground. Connector & terminal (E4) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE CONNECTOR. Measure the resistance of harness between ECM and purge control solenoid valve. Connector & terminal (B137) No. 6 — (E4) No. 2:

Is the voltage 10 V or more?

Go to step 4.

Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary open or short circuit of harness or temporary poor contact of connector may be the cause. Repair the power supply circuit.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the ground short circuit of harness between ECM and purge control solenoid valve connector.

Is the resistance less than 1 Ω? Go to step 6.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and purge control solenoid valve connector • Poor contact of coupling connector Replace the purge control solenoid valve.

CHECK PURGE CONTROL SOLENOID Is the resistance 10 — 100 Ω? VALVE. 1) Remove the purge control solenoid valve. 2) Measure the resistance between purge control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4SO)(diag)-215

Repair the poor contact of purge control solenoid valve connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BP:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1 B: B135

D: B137

ECM

E

41

48

B38

15

1

B4

D6

B220

i3

B21 E2

9

10

i54 R99

PURGE CONTROL SOLENOID VALVE

DRAIN VALVE

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

i54 1 2 3 4 5 6 7 8 9 10 11 12 13

2

1

E4

2

1

R144

D:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B220

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B137

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E4 R144 1 2

1 2

EN(H4SO)(diag)-216

EN-07789

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? PURGE CONTROL SOLENOID VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 6 (+) — Chassis ground (–): CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 Ω? VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between purge control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4SO)(diag)-217

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and purge control solenoid valve connector.

Replace the purge Repair the poor control solenoid contact of ECM valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BQ:DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the fuel level sensor and fuel sub level sensor.

BR:DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW NOTE: For the diagnostic procedure, refer to DTC P0463.

BS:DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0462 or P0463 displayed on the Subaru Select Monitor?

EN(H4SO)(diag)-218

Yes Check the combination meter.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BT:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check Yes CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0464 displayed on the Check the combidisplay? nation meter.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

BU:DTC P0500 VEHICLE SPEED SENSOR “A” DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK DTC OF VDC. Check DTC of VDC.

Check Is DTC of VDC displayed?

EN(H4SO)(diag)-219

Yes No Perform the diag- Repair the poor nosis according to contact of ECM DTC.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BV:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start the engine. • Engine does not start. • Improper idling • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E

E57

6

4

5 1 2 3

E2

*

ELECTRONIC THROTTLE CONTROL

E

E57

B138

B21

1 2 3 4 5 6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220

34 42 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

A:

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 28 29 26 27

EN-07785

EN(H4SO)(diag)-220

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

No Go to step 2.

2

CHECK AIR CLEANER ELEMENT. 1) Turn the ignition switch to OFF. 2) Check the air cleaner element.

Go to step 3.

3

CHECK ELECTRONIC THROTTLE CONTROL. 1) Remove the electronic throttle control.

2) Check the electronic throttle control.

1

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Is there excessive clogging on Replace the air cleaner element. air cleaner element?

Are foreign matter found inside Remove foreign electronic throttle control? matter from electronic throttle control.

EN(H4SO)(diag)-221

Perform the diagnosis of DTC P2101.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BW:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Engine keeps running at higher speed than specified idle speed. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E

E57

6

4

5 1 2 3

E2

*

ELECTRONIC THROTTLE CONTROL

E

E57

B138

B21

1 2 3 4 5 6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220

34 42 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

A:

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07785

EN(H4SO)(diag)-222

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK AIR INTAKE SYSTEM. 1) Start and idle the engine. 2) Check the following items. • Loose installation of intake manifold and throttle body • Cracks of intake manifold gasket and throttle body gasket • Disconnection of vacuum hoses CHECK ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control.

3) Check the electronic throttle control.

Is there any fault in air intake system?

Yes No Check the appro- Go to step 2. priate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Repair air suction Go to step 3. and leaks.

Are foreign matter found inside Remove foreign electronic throttle control? matter from electronic throttle control.

EN(H4SO)(diag)-223

Perform the diagnosis of DTC P2101.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BX:DTC P0512 STARTER REQUEST CIRCUIT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: F/B No. 21 6

BATTERY MAIN SBF

SBF-5

4

2

2 B72

3 IGNITION SWITCH

STARTER RELAY

E

3

1

B493

INHIBITOR SWITCH P CVT

2

CVT

MT

MT

6

11

9

B12

T3

1

N

D

STARTER MOTOR

CVT

B501

R

T7

MT

CLUTCH STROKE SENSOR (CLUTCH START SWITCH)

12

CVT B14

M C16

B26

MT

B : B135 ECM C : B136

B493

B501

B72

1 2 3 4

1 2 3 4 5

1 2 3 4 5 6

T7

B12

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9 10 11 12

B : B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C : B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07701

EN(H4SO)(diag)-224

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 16 (+) — Chassis ground (–): NOTE: For CVT model, place the select lever in “P” range or “N” range.

EN(H4SO)(diag)-225

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Repair the short circuit to power supply in harness between ECM and starter relay connector.

No Go to step 2.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BY:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine does not start. • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY M/B No. 16 4 3

M/B No. 12

1 2

IGNITION SWITCH

B72

B220

BATTERY

F/B No. 12

SBF-5 3

C2 C30

B13 C1 D7

1

MAIN SBF

A : B134

E

B : B135 ECM C : B136

37 36 40 35 34

D3 A6 A4 A3 D1

D : B137

B21 E2

E

E

B21

A: 1 8 9 18 19 28 29

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

2 10 20 30

B:

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B220

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

41 47 54

B72

1 2 3 4 5 6

C:

D:

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

EN(H4SO)(diag)-226

EN-07702

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

BZ:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR NOTE: For the diagnostic procedure, refer to DTC P0607.

EN(H4SO)(diag)-227

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CA:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY M/B No. 16 4 3

M/B No. 12

1 2

B72

B220

IGNITION SWITCH

BATTERY

F/B No. 12

SBF-5 3

B13 C1 D7

C2 C30

1

MAIN SBF

ECM

A28

A19 A1 A2 A29

D3 A6 A4 A3 D1

D : B137 C4

C : B136

B135

A18

B:

A : B134

E B138

* * 17

37 36 40 35 34

20 39 38 19

18

B21

*

4

5 1 2 3

E

E

ELECTRONIC THROTTLE CONTROL

E57

E

B220

B138

B21

B72

E57

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3 4 5 6

1 2 3 4 5 6

1 3 4 2

B136

D:

34 42

35 43 48

A: 1 8 9 18 19 28 29

2 10 20 30

36 49

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

37 44 50

38 45 51

39 52

40 46 53

: TERMINAL No. OPTIONAL ARRANGEMENT

6

E2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

41 47 54

B:

B135

C:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

EN(H4SO)(diag)-228

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 28 29 30 31 26 27

EN-07791

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK INPUT VOLTAGE OF ECM. Is the voltage 10 — 13 V? Go to step 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 1 (+) — Chassis ground (–): (B137) No. 7 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF ECM. Is the voltage 13 — 15 V? Go to step 3. 1) Start the engine. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 1 (+) — Chassis ground (–): (B137) No. 7 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 19 — (E57) No. 5: (B134) No. 29 — (E57) No. 3: CHECK ECM GROUND HARNESS. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 3 (+) — Chassis ground (–): (B134) No. 4 (+) — Chassis ground (–): (B134) No. 6 (+) — Chassis ground (–): (B137) No. 1 (+) — Chassis ground (–): (B137) No. 3 (+) — Chassis ground (–):

Is the voltage less than 1 V?

Repair the poor contact of ECM connector.

No Repair the open or ground short circuit of power supply circuit.

Repair the open or ground short circuit of power supply circuit.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in ground circuit • Retightening of engine ground terminals • Poor contact of coupling connector

CB:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1) NOTE: For the diagnostic procedure, refer to DTC P2101.

CC:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST) NOTE: For the diagnostic procedure, refer to CVT section.

EN(H4SO)(diag)-229

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CD:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

C: B136 ECM

*

: TERMINAL No. OPTIONAL ARRANGEMENT

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

4

35

C: B136

B25

T2

T2

CVT

B25

* *

1 2

B25

B12

1

2

MT

B138

1 2 3 4 5 6 7 8 9 10 11 12

NEUTRAL POSITION SWITCH

T7 INHIBITOR SWITCH P

B12

12

6

11

9 T3

R

N

D 1 2 3 4 5 6 7 8 9

T7 B138 1 2 3 4 5 6 7 8

CVT

STARTER MOTOR (MAGNET)

MT

M

MT

CVT

B14

TO STARTER RELAY

EN-07792

1

Step CHECK SELECT CABLE.

Check Is there any fault in select cable?

EN(H4SO)(diag)-230

Yes Repair or adjust the select cable.

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

4

Step CHECK INPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Place the select lever in other than “P” range and “N” range. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 35 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND TRANSMISSION HARNESS CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and transmission harness connector (T3). 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 35 — Chassis ground: CHECK TRANSMISSION HARNESS CONNECTOR. 1) Disconnect the connector from inhibitor switch. 2) Measure the resistance between transmission harness connector and engine ground. Connector & terminal (T3) No. 12 — Engine ground:

Check Is the voltage 10 V or more?

Yes Repair the poor contact of ECM connector.

No Go to step 3.

Is the resistance 1 MΩ or more?

Go to step 4.

Repair the ground short circuit of harness between ECM and transmission harness connector.

Is the resistance 1 MΩ or more?

Replace the inhibitor switch.

Repair the ground short circuit of harness between transmission harness connector and inhibitor switch connector.

EN(H4SO)(diag)-231

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CE:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

C: B136 ECM

*

: TERMINAL No. OPTIONAL ARRANGEMENT

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

4

35

C: B136

B25

T2

T2

CVT

B25

* *

1 2

B25

B12

1

2

MT

B138

1 2 3 4 5 6 7 8 9 10 11 12

NEUTRAL POSITION SWITCH

T7 INHIBITOR SWITCH P

B12

12

6

11

9 T3

R

N

D 1 2 3 4 5 6 7 8 9

T7 B138 1 2 3 4 5 6 7 8

CVT

STARTER MOTOR (MAGNET)

MT

M

MT

CVT

B14

TO STARTER RELAY

EN-07792

EN(H4SO)(diag)-232

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK INPUT SIGNAL OF ECM. Is the voltage 10 V or more? 1) Turn the ignition switch to ON. 2) Place the shift lever in a position other than neutral. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 35 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or NEUTRAL POSITION SWITCH CONNECmore? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and neutral position switch. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 35 — Chassis ground:

EN(H4SO)(diag)-233

Yes Repair the poor contact of ECM connector.

No Go to step 2.

Replace the neutral position switch.

Repair the short circuit to ground harness between ECM and neutral position switch connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CF:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

C: B136 ECM

*

: TERMINAL No. OPTIONAL ARRANGEMENT

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

4

35

C: B136

B25

T2

T2

CVT

B25

* *

1 2

B25

B12

1

2

MT

B138

1 2 3 4 5 6 7 8 9 10 11 12

NEUTRAL POSITION SWITCH

T7 INHIBITOR SWITCH P

B12

12

6

11

9 T3

R

N

D 1 2 3 4 5 6 7 8 9

T7 B138 1 2 3 4 5 6 7 8

CVT

STARTER MOTOR (MAGNET)

MT

M

MT

CVT

B14

TO STARTER RELAY

EN-07792

1

Step CHECK SELECT CABLE.

Check Is there any fault in select cable?

EN(H4SO)(diag)-234

Yes Repair or adjust the select cable.

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

4

Step Check CHECK INPUT SIGNAL OF ECM. Is the voltage less than 1 V? 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground with select lever at “P” range and “N” range. Connector & terminal (B136) No. 35 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 Ω? HIBITOR SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and inhibitor switch. 3) Measure the resistance of harness between ECM and inhibitor switch connector. Connector & terminal (B136) No. 35 — (T7) No. 6:

Yes Repair the poor contact of ECM connector.

Go to step 4.

No Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and inhibitor switch connector • Poor contact of coupling connector CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5 Ω? Replace the inhibi- Repair the harness Measure the resistance of harness between tor switch. In this case, repair (T7) No. 9 — Engine ground: the following item: • Open circuit of harness between inhibitor switch connector and starter motor ground line • Poor contact of coupling connector • Poor contact of starter motor connector • Poor contact of starter motor ground • Starter motor

EN(H4SO)(diag)-235

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CG:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

C: B136 ECM

*

: TERMINAL No. OPTIONAL ARRANGEMENT

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

4

35

C: B136

B25

T2

T2

CVT

B25

* *

1 2

B25

B12

1

2

MT

B138

1 2 3 4 5 6 7 8 9 10 11 12

NEUTRAL POSITION SWITCH

T7 INHIBITOR SWITCH P

B12

12

6

11

9 T3

R

N

D 1 2 3 4 5 6 7 8 9

T7 B138 1 2 3 4 5 6 7 8

CVT

STARTER MOTOR (MAGNET)

MT

M

MT

CVT

B14

TO STARTER RELAY

EN-07792

EN(H4SO)(diag)-236

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check CHECK INPUT SIGNAL OF ECM. Is the voltage less than 1 V? 1) Turn the ignition switch to ON. 2) Place the shift lever in neutral. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 35 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? NEUTRAL POSITION SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and neutral position switch. 3) Measure the resistance of harness between ECM and neutral position switch connector. Connector & terminal (B136) No. 35 — (B25) No. 2: (B136) No. 4 — (B25) No. 1: CHECK NEUTRAL POSITION SWITCH. 1) Place the shift lever in neutral. 2) Measure the resistance between neutral position switch terminals. Terminals No. 1 — No. 2:

Yes Repair the poor contact of ECM connector.

No Go to step 2.

Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and neutral position switch connector • Poor contact of joint connector Replace the neutral position switch.

Is the resistance less than 1 Ω? Repair the poor contact of neutral position switch connector.

EN(H4SO)(diag)-237

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CH:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

10

5 7 8 6

1 3 4 2

50

11

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8 B21

4 3

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

37

D3

D: B137

2 10 20 30

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07782

1

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H4SO)(diag)-238

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 18 — (E24) No. 2: (B136) No. 19 — (E24) No. 1: CHECK FOR POOR CONTACT. Is there poor contact of front Check for poor contact of the front oxygen (A/F) oxygen (A/F) sensor connecsensor connector. tor?

EN(H4SO)(diag)-239

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the poor Replace the front contact of front oxygen (A/F) senoxygen (A/F) sen- sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CI: DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

10

5 7 8 6

1 3 4 2

50

11

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8 B21

4 3

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

37

D3

D: B137

2 10 20 30

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07782

1

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H4SO)(diag)-240

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

4

5

Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 18 — Chassis ground: (B136) No. 19 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 19 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 18 (+) — Chassis ground (–):

Check Is the resistance 1 MΩ or more?

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

Is the voltage 4.5 V or more?

Go to step 5.

Go to step 4.

Is the voltage 4.95 V or more? Go to step 5.

Is the voltage 8 V or more? CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 18 (+) — Chassis ground (–): (B136) No. 19 (+) — Chassis ground (–):

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Replace the front oxygen (A/F) sensor. Repair the poor contact of ECM connector.

CJ:DTC P1160 RETURN SPRING FAILURE NOTE: For the diagnostic procedure, refer to DTC P2101.

EN(H4SO)(diag)-241

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CK:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper fuel supply CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1 B: B135

D: B137

ECM

E

41

48

B38

15

1

B4

D6

B220

i3

B21 E2

9

10

i54 R99

PURGE CONTROL SOLENOID VALVE

DRAIN VALVE

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

i54 1 2 3 4 5 6 7 8 9 10 11 12 13

2

1

E4

2

1

R144

D:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B220

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B137

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E4 R144 1 2

1 2

EN(H4SO)(diag)-242

EN-07789

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2 3

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK DRAIN HOSE. Is there clogging in the drain hose? Check the drain hose for clogging. CHECK DRAIN VALVE OPERATION. Does the drain valve operate? 1) Turn the ignition switch to OFF. 2) Install the delivery (test) mode fuse. 3) Turn the ignition switch to ON. 4) Operate the drain valve. NOTE: Drain valve can be operated using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

EN(H4SO)(diag)-243

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Replace the drain hose. Repair the poor contact of ECM connector.

No Go to step 2.

Go to step 3. Replace the drain valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CL:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) NOTE: For the diagnostic procedure, refer to DTC P1498.

CM:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT) NOTE: For the diagnostic procedure, refer to DTC P1499.

CN:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT) NOTE: For the diagnostic procedure, refer to DTC P1498.

CO:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT) NOTE: For the diagnostic procedure, refer to DTC P1499.

CP:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT) NOTE: For the diagnostic procedure, refer to DTC P1498.

CQ:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT) NOTE: For the diagnostic procedure, refer to DTC P1499.

EN(H4SO)(diag)-244

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CR:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine breathing CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode .

EN(H4SO)(diag)-245

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

WIRING DIAGRAM: E18 BATTERY

MAIN RELAY

1 2 3 4 5 6

M/B No. 16 4 3 B21 48

2 1

B220

E2

B220

5 7 8 6

9 11 12 10

13 15 16 14

5 2

1 3 4 2

EGR VALVE

B21

E

E18

17 18 20 21 19

6 3 4 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

30 25 29 26

E2

36

A30 A8 A20 A9

B21

A: B134

A: B134 1 8 9 18 19 28 29

ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1

A3

A4

A6

D3

D: B137

2 10 20 30

34

35

40

36

37

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

B21 E2

E

E EN-07788

1

Step Check CHECK POWER SUPPLY TO EGR VALVE. Is the voltage 10 V or more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from EGR valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between EGR valve connector and engine ground. Connector & terminal (E18) No. 2 (+) — Engine ground (–): (E18) No. 5 (+) — Engine ground (–):

EN(H4SO)(diag)-246

Yes Go to step 2.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between EGR valve and main relay connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. EGR VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and EGR valve connector. Connector & terminal DTC P1492; (B134) No. 8 — (E18) No. 3: DTC P1494; (B134) No. 9 — (E18) No. 1: DTC P1496; (B134) No. 20 — (E18) No. 4: DTC P1498; (B134) No. 30 — (E18) No. 6: CHECK HARNESS BETWEEN ECM AND EGR VALVE CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal DTC P1492; (B134) No. 8 — Chassis ground: DTC P1494; (B134) No. 9 — Chassis ground: DTC P1496; (B134) No. 20 — Chassis ground: DTC P1498; (B134) No. 30 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM and EGR valve connector.

Is the resistance 1 MΩ or more?

Go to step 4.

Is there poor contact of ECM or Repair the poor EGR valve connector? contact of ECM or EGR valve connector.

EN(H4SO)(diag)-247

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and EGR valve connector • Poor contact of coupling connector Repair the ground short in harness between ECM and EGR valve connector.

Replace the EGR valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CS:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine breathing CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode .

EN(H4SO)(diag)-248

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

WIRING DIAGRAM: E18 BATTERY

MAIN RELAY

1 2 3 4 5 6

M/B No. 16 4 3 B21 48

2 1

B220

E2

B220

5 7 8 6

9 11 12 10

13 15 16 14

5 2

1 3 4 2

EGR VALVE

B21

E

E18

17 18 20 21 19

6 3 4 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

30 25 29 26

E2

36

A30 A8 A20 A9

B21

A: B134

A: B134 1 8 9 18 19 28 29

ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1

A3

A4

A6

D3

D: B137

2 10 20 30

34

35

40

36

37

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

B21 E2

E

E EN-07788

1

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? EGR VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and EGR valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal DTC P1493; (B134) No. 8 (+) — Chassis ground (–): DTC P1495; (B134) No. 9 (+) — Chassis ground (–): DTC P1497; (B134) No. 20 (+) — Chassis ground (–): DTC P1499; (B134) No. 30 (+) — Chassis ground (–):

EN(H4SO)(diag)-249

Yes No Repair the short Go to step 2. circuit to power in the harness between the ECM and EGR valve connectors.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step CHECK EGR VALVE. Measure the resistance between EGR valve terminals. Terminals DTC P1493; No. 2 — No. 3: DTC P1493; No. 5 — No. 3: DTC P1495; No. 2 — No. 1: DTC P1495; No. 5 — No. 1: DTC P1497; No. 2 — No. 4: DTC P1497; No. 5 — No. 4: DTC P1499; No. 2 — No. 6: DTC P1499; No. 5 — No. 6:

Check Yes Is the resistance 20 Ω or more? Repair the poor contact of ECM connector.

EN(H4SO)(diag)-250

No Replace the EGR valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CT:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: F/B No. 21 6

BATTERY MAIN SBF

SBF-5

4

2

2 B72

3 IGNITION SWITCH

STARTER RELAY

E

3

1

B493

INHIBITOR SWITCH P CVT

MT

12

2

CVT

MT

11

1

D

T7 STARTER MOTOR

CVT

B501

N

9 T3

MT

CLUTCH STROKE SENSOR (CLUTCH START SWITCH)

B12

R

6

CVT B14

M C16

B26

MT

B : B135 ECM C : B136

B493

B501

B72

1 2 3 4

1 2 3 4 5

1 2 3 4 5 6

T7

B12

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9 10 11 12

B : B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C : B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07701

EN(H4SO)(diag)-251

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. NOTE: Check the followSTARTER RELAY CONNECTOR. ing item and repair 1) Turn the ignition switch to OFF. or replace if neces2) Remove the starter relay. sary. 3) Disconnect the connectors from ECM and • Open circuit of starter motor. harness between 4) Measure the resistance of harness between ECM and starter ECM and starter relay connector. relay connector Connector & terminal • Poor contact of (B136) No. 16 — (B493) No. 3: coupling connector NOTE: For CVT model, place the select lever in “P” range or “N” range. CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or Repair the poor Repair the short STARTER RELAY CONNECTOR. more? contact of ECM circuit to ground in Measure the resistance between ECM and connector. harness between chassis ground. ECM and starter Connector & terminal relay connector. (B136) No. 16 — Chassis ground:

EN(H4SO)(diag)-252

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CU:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY M/B No. 16 4 3

M/B No. 12

1 2

IGNITION SWITCH

B72

B220

BATTERY

F/B No. 12

SBF-5 3

C2 C30

B13 C1 D7

1

MAIN SBF

A : B134

E

B : B135 ECM C : B136

37 36 40 35 34

D3 A6 A4 A3 D1

D : B137

B21 E2

E

E

B21

A: 1 8 9 18 19 28 29

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B220

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

41 47 54

B72

1 2 3 4 5 6

1

2 10 20 30

B:

B134

C:

D:

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

Step CHECK INPUT SIGNAL OF ECM. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 2 (+) — Chassis ground (–):

5 6 14 15 16 25 26 27 33 34 35

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

Check Is the voltage 10 V or more?

EN(H4SO)(diag)-253

EN-07702

Yes Repair the poor contact of ECM connector.

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or MAIN FUSE BOX CONNECTOR. more? 1) Disconnect the connector from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 2 — Chassis ground: CHECK M/B FUSE NO. 12 (MAIN FUSE BOX). Is the fuse blown out?

EN(H4SO)(diag)-254

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and battery terminal.

Replace the fuse.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and battery • Poor contact of ECM connector • Poor contact of battery terminal

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CV:DTC P1602 CONTROL MODULE PROGRAMMING ERROR DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine keeps running at higher speed than specified idle speed. • Engine keeps running at a lower speed than the specified idle speed. • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

MAIN RELAY M/B No. 16 4 3 2 1

E

B220

13 45

12 44

11

ECM

43

42

48

10

B134

B21 E2

FUEL INJECTOR No. 1

E5

E16

E6

E17

1 2

FUEL INJECTOR No. 2

FUEL INJECTOR No. 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 43 48

36 49

37 44 50

38 45 51

1

2

E17

FUEL INJECTOR No. 4

B134

B21

34 42

1

2

E6

1

2

E16

1

2

E5

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B220

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

41 47 54

EN-07705

EN(H4SO)(diag)-255

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E

E57

6

4

5 1 2 3

E2

*

ELECTRONIC THROTTLE CONTROL

E

E57

B138

B21

1 2 3 4 5 6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220

34 42 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

A:

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

B:

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 28 29 26 27

EN-07785

1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

2

CHECK ENGINE OIL.

Is there a proper amount of engine oil?

3

CHECK EXHAUST SYSTEM.

Are there holes or loose bolts on exhaust system?

EN(H4SO)(diag)-256

Yes No Check the appro- Go to step 2. priate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Go to step 3. Replace engine oil.

Repair the exhaust Go to step 4. system.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

4

5

6

7

Step CHECK AIR INTAKE SYSTEM.

Check Yes Are there holes, loose bolts or Repair the air disconnection of hose on air intake system. intake system? CHECK FUEL PRESSURE. Is the measured value 339.5 — Go to step 6. 360.5 kPa (3.5 — 3.7 kg/cm2, WARNING: Place “NO OPEN FLAMES” signs near the 49 — 52 psi)? working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the temperature 75°C Go to step 7. SENSOR. (167°F) or more? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR Is the measured value 2.0 — Go to step 8. TEMPERATURE SENSOR. 5.0 g/s (0.26 — 0.66 lb/m)? 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) For CVT models, set the select lever to “P” range or “N” range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H4SO)(diag)-257

No Go to step 5.

Repair the following item. Fuel pressure is too high: • Clogged fuel line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel line Replace the engine coolant temperature sensor.

Replace the mass air flow and intake air temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

8

9

10

11

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) For CVT models, set the select lever to “P” range or “N” range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Measure the resistance between fuel injector connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 — Engine ground: #2 (E16) No. 1 — Engine ground: #3 (E6) No. 1 — Engine ground: #4 (E17) No. 1 — Engine ground: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure the resistance of harness between ECM and fuel injector on faulty cylinders. Connector & terminal #1 (B134) No. 10 — (E5) No. 1: #2 (B134) No. 11 — (E16) No. 1: #3 (B134) No. 12 — (E6) No. 1: #4 (B134) No. 13 — (E17) No. 1:

Check Yes Subtract ambient temperature Go to step 9. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

No Check the mass air flow and intake air temperature sensor.

Is the voltage 10 V or more?

Go to step 14.

Go to step 10.

Is the resistance 1 MΩ or more?

Go to step 11.

Repair the ground short circuit of harness between ECM and fuel injector connector.

Is the resistance less than 1 Ω? Go to step 12.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel injector connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

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13

14

15

16

17

Step CHECK FUEL INJECTOR. Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK POWER SUPPLY LINE. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel injector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 2 (+) — Engine ground (–): #2 (E16) No. 2 (+) — Engine ground (–): #3 (E6) No. 2 (+) — Engine ground (–): #4 (E17) No. 2 (+) — Engine ground (–):

Check Is the resistance 5 — 20 Ω?

Yes Go to step 13.

No Replace the faulty fuel injector.

Is the voltage 10 V or more?

Repair the poor contact of all connectors in fuel injector circuit.

CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–): CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK INSTALLATION CONDITION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR.

Is the voltage 10 V or more?

Repair the short circuit to power in the harness between the ECM and fuel injector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between the main relay connector and fuel injector connector on faulty cylinders • Poor contact of coupling connector • Poor contact of main relay connector Go to step 15.

Is the resistance less than 1 Ω? Replace the faulty Go to step 16. fuel injector.

Is the camshaft position sensor Tighten the cam- Go to step 17. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. CHECK CRANK SPROCKET. Is the crank sprocket rusted or Replace the crank Go to step 18. Remove the timing belt cover.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

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19

20

21

22

23

Step CHECK INSTALLATION CONDITION OF TIMING BELT. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 499987500 CRANKSHAFT SOCKET CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 13 and No. 14 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 15 — No. 16: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Disconnect the connector from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 — Chassis ground: (B220) No. 15 — Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B135) No. 17 — (B220) No. 14: (B135) No. 7 — (B220) No. 15:

Check Is the timing belt dislocated from its proper position?

Yes No Repair the installa- Go to step 19. tion condition of timing belt.

Is the resistance less than 1 Ω? Go to step 20.

Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Go to step 21.

Repair the open or ground short circuit of power supply circuit.

Is the voltage 10 V or more?

Repair the short Go to step 22. circuit to power in the harness between ECM and electronic throttle control relay connector.

Is the resistance 1 MΩ or more?

Go to step 23.

Repair the short circuit in harness to ground between ECM and electronic throttle control relay connector.

Is the resistance less than 1 Ω? Go to step 24.

Repair the open circuit in harness between ECM and electronic throttle control relay connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

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25

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: (B134) No. 28 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground: (E57) No. 4 — Engine ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 25.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 26.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 29.

26

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 27. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

27

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 28. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

28

CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): (E57) No. 4 (+) — Engine ground (–):

Is the voltage 5 V or more?

EN(H4SO)(diag)-261

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

29

30

31

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18: (B134) No. 19 — (B134) No. 28: CHECK SENSOR OUTPUT. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. CHECK SENSOR OUTPUT. Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

Check Is the resistance 1 MΩ or more?

Yes Go to step 30.

No Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Is the voltage 0.81 — 0.87 V?

Go to step 31.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Is the voltage 1.64 — 1.70 V?

Go to step 32.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Go to step 34.

32

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 33. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and electronic throttle control connector. Connector & terminal (B134) No. 2 — (E57) No. 2: (B134) No. 1 — (E57) No. 1:

33

CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 (+) — Engine ground (–): (E57) No. 1 (+) — Engine ground (–):

Is the voltage 5 V or more?

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Repair the short circuit to power in the harness between ECM and electronic throttle control.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

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35

36

37

38

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 — Engine ground: (E57) No. 1 — Engine ground: CHECK HARNESS BETWEEN ELECTRONIC THROTTLE CONTROL CONNECTOR. Measure the resistance between electronic throttle control connectors. Connector & terminal (E57) No. 2 — (E57) No. 1: CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 35.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 36.

Repair the short circuit of harness between ECM and electronic throttle control connector.

Is the resistance less than 5 Ω? Go to step 37.

CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 2 — No. 1: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers.

Is the resistance 50 Ω or less? Go to step 38.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector Replace the electronic throttle control.

Does the valve return to the Repair the poor specified position? Standard contact of ECM value: 3 mm (0.12 in) from fully connector. closed position

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Replace the electronic throttle control.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CW:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12 50

10

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

11

5 7 8 6

1 3 4 2

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8

4 3

B21 B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

D3

D: B137

37

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07782

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BATTERY

A/F, OXYGEN SENSOR RELAY

B220

M/B No. 15 12

B21

E2

5 7 8 6

17 18 20 21 19

13 15 16 14

9 11 12 10

2

10

1 3 4 2

50

11

9

E

REAR OXYGEN SENSOR

B220

E25

B503

E25

1 3

3

4

1

1 2 3 4 5 6 7 8 2 4

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1

19

53

E2 B21

E

34 42

35 43 48

C20 C9

A29

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

A: B134

* * B6

36

1 8 9 18 19 28 29

B503

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

A: B134

B: B135 B: B135 ECM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

C: B136

D1 34

A4

A6

A3 35

40

36

37

D3

D: B137

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1

2

E

*

: TERMINAL No. OPTIONAL ARRANGEMENT

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07783

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. Has water entered the connec- Completely Go to step 3. tor? remove any water inside.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 19 — (E24) No. 1: (B136) No. 18 — (E24) No. 2:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 19 — Chassis ground: (B136) No. 18 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E24) No. 1 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 2 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 1 (+) — Chassis ground (–): (E24) No. 2 (+) — Chassis ground (–):

Is the resistance 1 MΩ or more?

Go to step 5.

Is the voltage 4.5 V or more?

Go to step 7.

Go to step 6.

Is the voltage 4.95 V or more? Go to step 7.

Go to step 8.

Is the voltage 8 V or more?

Repair the poor contact of ECM connector.

8

CHECK EXHAUST SYSTEM.

9

CHECK AIR INTAKE SYSTEM.

Are there holes or loose bolts on exhaust system? Are there holes, loose bolts or disconnection of hose on air intake system?

5

6

7

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Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Repair the exhaust system. Repair the air intake system.

Go to step 9. Go to step 10.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10

11

12

Step CHECK FUEL PRESSURE. WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) For CVT models, set the select lever to “P” range or “N” range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Yes Is the measured value 339.5 — Go to step 11. 360.5 kPa (3.5 — 3.7 kg/cm2, 49 — 52 psi)?

No Repair the following item. Fuel pressure is too high: • Clogged fuel line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel line

Is the temperature 75°C (167°F) or more?

Go to step 12.

Replace the engine coolant temperature sensor.

Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)?

Go to step 13.

Replace the mass air flow and intake air temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

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14

15

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) For CVT models, set the select lever to “P” range or “N” range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Depress the clutch pedal. (MT model) • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Depress the clutch pedal. (MT model) • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Yes Subtract ambient temperature Go to step 14. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

No Check the mass air flow and intake air temperature sensor.

Is the voltage 490 mV or more? Go to step 15.

Go to step 16.

Is the voltage 250 mV or less? Go to step 17.

Go to step 16.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

16

17

18

19

Step Check Yes CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK FRONT OXYGEN (A/F) SENSOR US- Is a voltage of 250 mV or less Replace the front ING REAR OXYGEN SENSOR SIGNAL. maintained for 5 minutes or oxygen (A/F) sen1) Warm up the engine until engine coolant more? sor. using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 19. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B134) No. 29 — (E25) No. 4:

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Is the voltage 0.2 — 0.5 V?

EN(H4SO)(diag)-269

No Go to step 18.

Go to step 18.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CX:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15 12 50

10

B21

13 15 16 14

9 11 12 10

17 18 20 21 19

E2

9 B220

4

11

5 7 8 6

1 3 4 2

E

FRONT OXYGEN (A/F) SENSOR

E24

2 1 4 3 2 1

3

E24

B503 1 2 3 4 5 6 7 8

4 3

B21 B21

E

C5 C6

C18 C19 C9

* *

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

A3

A4

A6

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 C: B136

D1 34

35

40

36

D3

D: B137

37

: TERMINAL No. OPTIONAL ARRANGEMENT

51

E2

*

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07782

EN(H4SO)(diag)-270

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BATTERY

A/F, OXYGEN SENSOR RELAY

B220

M/B No. 15 12

B21

E2

5 7 8 6

17 18 20 21 19

13 15 16 14

9 11 12 10

2

10

1 3 4 2

50

11

9

E

REAR OXYGEN SENSOR

B220

E25

B503

E25

1 3

3

4

1

1 2 3 4 5 6 7 8 2 4

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1

19

53

E2 B21

E

34 42

35 43 48

C20 C9

A29

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

A: B134

* * B6

36

1 8 9 18 19 28 29

B503

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

A: B134

B: B135 B: B135 ECM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

C: B136

D1 34

A4

A6

A3 35

40

36

37

D3

D: B137

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B21 E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1

2

E

*

: TERMINAL No. OPTIONAL ARRANGEMENT

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07783

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. Has water entered the connec- Completely Go to step 3. tor? remove any water inside.

EN(H4SO)(diag)-271

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 19 — (E24) No. 1: (B136) No. 18 — (E24) No. 2:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 19 — Chassis ground: (B136) No. 18 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E24) No. 1 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 2 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 1 (+) — Chassis ground (–): (E24) No. 2 (+) — Chassis ground (–):

Is the resistance 1 MΩ or more?

Go to step 5.

Is the voltage 4.5 V or more?

Go to step 7.

Go to step 6.

Is the voltage 4.95 V or more? Go to step 7.

Go to step 8.

Is the voltage 8 V or more?

Repair the poor contact of ECM connector.

8

CHECK EXHAUST SYSTEM.

9

CHECK AIR INTAKE SYSTEM.

Are there holes or loose bolts on exhaust system? Are there holes, loose bolts or disconnection of hose on air intake system?

5

6

7

EN(H4SO)(diag)-272

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Repair the exhaust system. Repair the air intake system.

Go to step 9. Go to step 10.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10

11

12

Step CHECK FUEL PRESSURE. WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) For CVT models, set the select lever to “P” range or “N” range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Yes Is the measured value 339.5 — Go to step 11. 360.5 kPa (3.5 — 3.7 kg/cm2, 49 — 52 psi)?

No Repair the following item. Fuel pressure is too high: • Clogged fuel line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel line

Is the temperature 75°C (167°F) or more?

Go to step 12.

Replace the engine coolant temperature sensor.

Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)?

Go to step 13.

Replace the mass air flow and intake air temperature sensor.

EN(H4SO)(diag)-273

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

13

14

15

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) For CVT models, set the select lever to “P” range or “N” range, and for MT models, place the shift lever in the neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Depress the clutch pedal. (MT model) • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Depress the clutch pedal. (MT model) • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Yes Subtract ambient temperature Go to step 14. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

No Check the mass air flow and intake air temperature sensor.

Is the voltage 490 mV or more? Go to step 15.

Go to step 16.

Is the voltage 250 mV or less? Go to step 17.

Go to step 16.

EN(H4SO)(diag)-274

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

16

17

18

19

Step Check Yes CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK FRONT OXYGEN (A/F) SENSOR US- Is a voltage of 0.8 V or more Replace the front ING REAR OXYGEN SENSOR SIGNAL. maintained for 5 minutes or oxygen (A/F) sen1) Warm up the engine until engine coolant more? sor. using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 19. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B134) No. 29 — (E25) No. 4:

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Is the voltage 0.2 — 0.5 V?

EN(H4SO)(diag)-275

No Go to step 18.

Go to step 18.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CY:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E

E57

6

4

5 1 2 3

E2

*

ELECTRONIC THROTTLE CONTROL

E

E57

B138

B21

1 2 3 4 5 6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220

34 42 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

A:

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07785

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 13 and No. 14 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 15 — No. 16: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Disconnect the connector from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 — Chassis ground: (B220) No. 15 — Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B135) No. 17 — (B220) No. 14: (B135) No. 7 — (B220) No. 15: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: (B134) No. 28 — Chassis ground:

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Go to step 3.

Repair the open or ground short circuit of power supply circuit.

Is the voltage 10 V or more?

Repair the short Go to step 4. circuit to power in the harness between ECM and electronic throttle control relay connector.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the short circuit in harness to ground between ECM and electronic throttle control relay connector.

Is the resistance less than 1 Ω? Go to step 6.

Repair the open circuit in harness between ECM and electronic throttle control relay connector.

Go to step 7.

Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

EN(H4SO)(diag)-277

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

7

Step Check CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 MΩ or 1) Connect the connector to ECM. more? 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground: (E57) No. 4 — Engine ground:

Yes Go to step 8.

8

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 9. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

9

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 10. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

10

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): (E57) No. 4 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL CON- more? NECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18: (B134) No. 19 — (B134) No. 28:

11

EN(H4SO)(diag)-278

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Go to step 12.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 11.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

12

13

Step Check CHECK SENSOR OUTPUT. Is the voltage 0.81 — 0.87 V? 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. CHECK SENSOR OUTPUT. Is the voltage 1.64 — 1.70 V? Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

Yes Go to step 13.

No Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Go to step 14.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Go to step 16.

14

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 15. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and electronic throttle control connector. Connector & terminal (B134) No. 2 — (E57) No. 2: (B134) No. 1 — (E57) No. 1:

15

CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 (+) — Engine ground (–): (E57) No. 1 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 — Engine ground: (E57) No. 1 — Engine ground: CHECK ELECTRONIC THROTTLE CONTROL CONNECTOR HARNESS. Measure the resistance between electronic throttle control connectors. Connector & terminal (E57) No. 2 — (E57) No. 1:

16

17

Is the voltage 5 V or more?

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 17.

Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 18.

Repair the short circuit of harness between ECM and electronic throttle control connector.

EN(H4SO)(diag)-279

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

18

19

20

Step CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

Check Yes Is the resistance less than 5 Ω? Go to step 19.

CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 2 — No. 1: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers.

Is the resistance 50 Ω or less? Go to step 20.

Does the valve return to the Repair the poor specified position? Standard contact of ECM value: 3 mm (0.12 in) from fully connector. closed position

EN(H4SO)(diag)-280

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector Replace the electronic throttle control. Replace the electronic throttle control.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CZ:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E

E57

6

4

5 1 2 3

E2

*

ELECTRONIC THROTTLE CONTROL

E

E57

B138

B21

1 2 3 4 5 6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220

34 42 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

A:

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07785

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 13 and No. 14 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 15 — No. 16: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Disconnect the connector from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 — Chassis ground: (B220) No. 15 — Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B135) No. 17 — (B220) No. 14: (B135) No. 7 — (B220) No. 15:

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Go to step 3.

Repair the open or ground short circuit of power supply circuit.

Is the voltage 10 V or more?

Repair the short Go to step 4. circuit to power in the harness between ECM and electronic throttle control relay connector.

Is the resistance 1 MΩ or more?

Go to step 5.

Is the resistance less than 1 Ω? Repair the poor contact of ECM connector.

EN(H4SO)(diag)-282

Repair the short circuit in harness to ground between ECM and electronic throttle control relay connector.

Repair the open circuit in harness between ECM and electronic throttle control relay connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DA:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E57

E

E57

1 2 3 4 5 6 7 8 B220

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

A:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

E

B21

34 42 1 3 4 2

*

ELECTRONIC THROTTLE CONTROL

B138

1 2 3 4 5 6

6

4

5 1 2 3

E2

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 28 29 26 27

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Measure the resistance between electronic throttle control relay terminals. Terminals No. 15 — No. 16: CHECK SHORT CIRCUIT OF ELECTRONIC THROTTLE CONTROL RELAY POWER SUPPLY. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 15 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 17 — Chassis ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Repair the short Go to step 3. circuit to power in the harness between ECM and electronic throttle control relay connector.

Is the resistance 1 MΩ or more?

Repair the poor contact of ECM connector.

Repair the short circuit in harness to ground between ECM and electronic throttle control relay connector.

DB:DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP PERFORMANCE NOTE: For the diagnostic procedure, refer to DTC P2101.

EN(H4SO)(diag)-284

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DC:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B315 1 2 3 4 5 6 ACCELERATOR PEDAL POSITION SENSOR

B83

2

3

1

5

6

4

B138 B315

1 2 3 4 5 6 7 8 B21

* *

* *

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B30

B31

B29

B23

B22

*

A: B134

: TERMINAL No. OPTIONAL ARRANGEMENT

A: B134 1 2 8 9 10 18 19 20 28 29 30

B: B135 ECM C: B136

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 D1

A3

A4

A6

B: B135 D3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C: B136

34

35

40

B21 36

C4

B21

B83

37

B138

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

E

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 21 — Chassis ground: (B135) No. 23 — Chassis ground: (B135) No. 23 — (B136) No. 4: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 — Chassis ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector.

Is the resistance 1 MΩ or more?

Replace the accelerator pedal.

Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective.

EN(H4SO)(diag)-286

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DD:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B315 1 2 3 4 5 6 ACCELERATOR PEDAL POSITION SENSOR

B83

2

3

1

5

6

4

B138 B315

1 2 3 4 5 6 7 8 B21

* *

* *

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B30

B31

B29

B23

B22

*

A: B134

: TERMINAL No. OPTIONAL ARRANGEMENT

A: B134 1 2 8 9 10 18 19 20 28 29 30

B: B135 ECM C: B136

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 D1

A3

A4

A6

B: B135 D3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C: B136

34

35

40

B21 36

C4

B21

B83

37

B138

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

E

EN-07793

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 Ω? Go to step 2. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance of harness between ECM and accelerator pedal position sensor connector. Connector & terminal (B135) No. 23 — (B315) No. 6: (B135) No. 29 — (B315) No. 5: CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Ω? Go to step 3. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 5 — Chassis ground:

CHECK HARNESS BETWEEN ECM AND AC- Is the voltage 5 V or more? CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 MΩ or CELERATOR PEDAL POSITION SENSOR more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B135) No. 21 — (B135) No. 23:

EN(H4SO)(diag)-288

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

Repair the poor contact of accelerator pedal position sensor connector. Replace the accelerator pedal if defective.

No Repair the open circuit of harness between ECM and accelerator pedal position sensor connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DE:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B315 1 2 3 4 5 6 ACCELERATOR PEDAL POSITION SENSOR

B83

2

3

1

5

6

4

B138 B315

1 2 3 4 5 6 7 8 B21

* *

* *

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B30

B31

B29

B23

B22

*

A: B134

: TERMINAL No. OPTIONAL ARRANGEMENT

A: B134 1 2 8 9 10 18 19 20 28 29 30

B: B135 ECM C: B136

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 D1

A3

A4

A6

B: B135 D3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C: B136

34

35

40

B21 36

C4

B21

B83

37

B138

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

E

EN-07793

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 22 — Chassis ground: (B135) No. 31 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 3 — Chassis ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector.

Is the resistance 1 MΩ or more?

Replace the accelerator pedal.

Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective.

EN(H4SO)(diag)-290

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DF:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B315 1 2 3 4 5 6 ACCELERATOR PEDAL POSITION SENSOR

B83

2

3

1

5

6

4

B138 B315

1 2 3 4 5 6 7 8 B21

* *

* *

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B30

B31

B29

B23

B22

*

A: B134

: TERMINAL No. OPTIONAL ARRANGEMENT

A: B134 1 2 8 9 10 18 19 20 28 29 30

B: B135 ECM C: B136

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 D1

A3

A4

A6

B: B135 D3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C: B136

34

35

40

B21 36

C4

B21

B83

37

B138

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

E

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 Ω? Go to step 2. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance of harness between ECM and accelerator pedal position sensor connector. Connector & terminal (B135) No. 31 — (B315) No. 3: (B135) No. 30 — (B315) No. 2:

2

CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 Ω? Go to step 3. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 2 — Chassis ground:

3

CHECK HARNESS BETWEEN ECM AND AC- Is the voltage 5 V or more? CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 3 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 MΩ or CELERATOR PEDAL POSITION SENSOR more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B135) No. 22 — (B135) No. 31:

4

EN(H4SO)(diag)-292

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

Repair the poor contact of accelerator pedal position sensor connector. Replace the accelerator pedal if defective.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and accelerator pedal position sensor connector. • Poor contact of joint connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of joint connector Go to step 4.

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DG:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13 B220 M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B220

B17

B7

E ECM D : B137

C : B136

A 18

A 28

D3 A6 A4 A3 D1

C4

B : B135

A 19 A1 A2 A 29

A : B134

* *

B21

17

18

20 39 38 19

37 36 40 35 34

B138

E

E

E57

6

4

5 1 2 3

E2

*

ELECTRONIC THROTTLE CONTROL

E

E57

B138

B21

1 2 3 4 5 6

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220

34 42 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

35 43 48

36 49

37 44 50

: TERMINAL No. OPTIONAL ARRANGEMENT

A:

38 45 51

39 52

40 46 53

41 47

1 2 8 9 10 18 19 20 28 29 30

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

C:

B136

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31 D:

B137

54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07785

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: (B134) No. 28 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground: (E57) No. 4 — Engine ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 6.

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

4

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 5. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

5

CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): (E57) No. 4 (+) — Engine ground (–):

Is the voltage 5 V or more?

EN(H4SO)(diag)-294

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL CON- more? NECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18: (B134) No. 19 — (B134) No. 28:

EN(H4SO)(diag)-295

Yes Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

No Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DH:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B315 1 2 3 4 5 6 ACCELERATOR PEDAL POSITION SENSOR

B83

2

3

1

5

6

4

B138 B315

1 2 3 4 5 6 7 8 B21

* *

* *

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B30

B31

B29

B23

B22

*

A: B134

: TERMINAL No. OPTIONAL ARRANGEMENT

A: B134 1 2 8 9 10 18 19 20 28 29 30

B: B135 ECM C: B136

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 D1

A3

A4

A6

B: B135 D3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C: B136

34

35

40

B21 36

C4

B21

B83

37

B138

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

E2

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

E

EN-07793

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal Main accelerator pedal position sensor signal (B135) No. 23 (+) — Chassis ground (–): Sub accelerator pedal position sensor signal (B135) No. 31 (+) — Chassis ground (–): CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 (+) — Chassis ground (–): (B315) No. 3 (+) — Chassis ground (–):

Check Yes Is the difference between the Go to step 3. measured value of main accelerator pedal position sensor signal and the measured value of sub accelerator pedal position sensor signal 0 V?

No Go to step 2.

Is the difference between the measured value of main accelerator pedal position sensor signal and the measured value of sub accelerator pedal position sensor signal 0 V?

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and accelerator pedal position sensor connector. • Ground short circuit of harness between ECM and accelerator pedal position sensor connector. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and accelerator pedal position sensor connector. • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of joint connector

Replace the accelerator pedal.

CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Ω? Repair the poor CELERATOR PEDAL POSITION SENSOR contact of ECM CONNECTOR. connector. Measure the resistance of harness between the accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 5 — Chassis ground: (B315) No. 2 — Chassis ground:

EN(H4SO)(diag)-297

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DI: DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check DTC using “List of Diagnostic Trouble Code (DTC)”.

No Replace the ECM.

NOTE: The barometric pressure sensor is built into the ECM.

DJ:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H4SO)(diag)-298

Yes Check DTC using “List of Diagnostic Trouble Code (DTC)”.

No Replace the ECM.

NOTE: The barometric pressure sensor is built into the ECM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DK:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check DTC using “List of Diagnostic Trouble Code (DTC)”.

No Replace the ECM.

NOTE: The barometric pressure sensor is built into the ECM.

DL:DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION NOTE: For the diagnostic procedure, refer to LAN section.

DM:DTC U0101 CAN (TCU) DATA NOT LOADED NOTE: For the diagnostic procedure, refer to LAN section.

DN:DTC U0122 CAN (VDC) DATA NOT LOADED NOTE: For the diagnostic procedure, refer to LAN section.

DO:DTC U0140 CAN (BCU) DATA NOT LOADED NOTE: For the diagnostic procedure, refer to LAN section.

DP:DTC U0402 CAN (TCU) DATA ABNORMAL NOTE: For the diagnostic procedure, refer to LAN section.

DQ:DTC U0416 CAN (VDC) DATA ABNORMAL NOTE: For the diagnostic procedure, refer to LAN section.

DR:DTC U0422 CAN (BCU) DATA ABNORMAL NOTE: For the diagnostic procedure, refer to LAN section.

EN(H4SO)(diag)-299

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General Diagnostic Table ENGINE (DIAGNOSTICS)

19.General Diagnostic Table A: INSPECTION 1. ENGINE NOTE: Malfunction of parts other than those listed is also possible. Symptoms

1. Engine stalls during idling.

2. Rough idling

3. Engine does not return to idle.

4. Poor acceleration

Problem parts 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Ignition parts (*1) 4) Engine coolant temperature sensor (*2) 5) Crankshaft position sensor (*3) 6) Camshaft position sensor (*3) 7) Fuel injection parts (*4) 8) Electronic throttle control 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Ignition parts (*1) 5) Air intake system (*5) 6) Fuel injection parts (*4) 7) Electronic throttle control 8) Crankshaft position sensor (*3) 9) Camshaft position sensor (*3) 10) Oxygen sensor 11) Fuel pump and fuel pump relay 12) EGR valve 13) Oil switching solenoid valve 1) Engine coolant temperature sensor 2) Electronic throttle control 3) Manifold absolute pressure sensor 4) Mass air flow and intake air temperature sensor 5) EGR valve 6) Accelerator pedal position sensor 7) Oil temperature sensor 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Electronic throttle control 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay 6) Engine coolant temperature sensor (*2) 7) Crankshaft position sensor (*3) 8) Camshaft position sensor (*3) 9) Engine torque control signal circuit 10) Ignition parts (*1) 11) EGR valve 12) Accelerator pedal position sensor 13) Oil temperature sensor 14) Oil switching solenoid valve

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General Diagnostic Table ENGINE (DIAGNOSTICS) Symptoms

Problem parts 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5. Engine stalls, hesitates, or sputters at accelera- 5) Camshaft position sensor (*3) tion. 6) Purge control solenoid valve 7) Fuel injection parts (*4) 8) Electronic throttle control 9) Fuel pump and fuel pump relay 10) EGR valve 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5) Camshaft position sensor (*3) 6. Surging 6) Fuel injection parts (*4) 7) Electronic throttle control 8) Fuel pump and fuel pump relay 9) EGR valve 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor 4) Knock sensor 7. Spark knock 5) Fuel injection parts (*4) 6) Fuel pump and fuel pump relay 7) EGR valve 8) Oil switching solenoid valve 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 8. After-burning in exhaust system 3) Engine coolant temperature sensor (*2) 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay *1:

Check ignition coil and spark plug. *2: Indicate the symptom occurring only in cold temperatures. *3: Ensure the secure installation. *4: Check fuel injector, fuel pressure regulator and fuel filter. *5: Inspect air leak in air intake system.

EN(H4SO)(diag)-301

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General Diagnostic Table ENGINE (DIAGNOSTICS)

EN(H4SO)(diag)-302

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GENERAL DESCRIPTION

GD(H4SO) 1. 2.

Page List of Diagnostic Trouble Code (DTC) ......................................................2 Diagnostic Trouble Code (DTC) Detecting Criteria ....................................8

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION

1. List of Diagnostic Trouble Code (DTC) A: LIST DTC P0026

Item Intake Valve Control Solenoid Circuit Range/Performance (Bank 1)

P0028

Intake Valve Control Solenoid Circuit Range/Performance (Bank 2)

P0030

HO2S Heater Control Circuit (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 1)

P0031

P0032

HO2S Heater Control Circuit High (Bank 1 Sensor 1)

P0037

HO2S Heater Control Circuit Low (Bank 1 Sensor 2)

P0038

HO2S Heater Control Circuit High (Bank 1 Sensor 2)

P0068

MAP/MAF - Throttle Position Correlation Intake Valve Control Solenoid Circuit Low (Bank 1) Intake Valve Control Solenoid Circuit High (Bank 1) Intake Valve Control Solenoid Circuit Low (Bank 2) Intake Valve Control Solenoid Circuit High (Bank 2) Mass or Volume Air Flow Circuit Range/Performance

P0076 P0077 P0082 P0083 P0101

P0102 P0103 P0107

Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input

P0108

Manifold Absolute Pressure/Barometric Pressure Circuit High Input

P0111

Intake Air Temperature Sensor 1 Circuit Range/Performance

P0112

Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low

P0113 P0117

Index















GD(H4SO)-2

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0118 P0122

Item Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/Switch “A” Circuit Low

P0123

Throttle/Pedal Position Sensor/Switch “A” Circuit High

P0125

Insufficient Coolant Temperature for Closed Loop Fuel Control

P0126

Insufficient Engine Coolant Temperature for Stable Operation

P0128

Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)

P0131 P0132 P0133

P0134

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)

P0137

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)

P0138 P0139

P0140

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)

P0141 P0171

O2 Sensor Heater Circuit (Bank1 Sensor2) System Too Lean (Bank 1)

P0172

System Too Rich (Bank 1)

P0181

Fuel Temperature Sensor “A” Circuit Range/Performance

P0182

Fuel Temperature Sensor “A” Circuit Low Input Fuel Temperature Sensor “A” Circuit High Input Engine Oil Temperature Sensor Circuit Range/Performance

P0183 P0196

P0197

Engine Oil Temperature Sensor Low

Index















GD(H4SO)-3

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0198 P0222

P0223

P0301 P0302 P0303 P0304 P0327

P0328

P0335 P0336

P0340

P0341

P0400 P0420

P0442

P0447

P0448

P0451

P0452

P0453

Item Engine Oil Temperature Sensor High

Index

Throttle/Pedal Position Sensor/Switch Throttle/Pedal Position Sensor/Switch Cylinder 1 Misfire Detected

Cylinder 2 Misfire Detected

Cylinder 3 Misfire Detected

Cylinder 4 Misfire Detected

Knock Sensor 1 Circuit Low (Bank 1

Knock Sensor 1 Circuit High (Bank 1 Crankshaft Position Sensor “A” Circuit Crankshaft Position Sensor “A” Circuit Camshaft Position Sensor “A” Circuit Camshaft Position Sensor “A” Circuit Exhaust Gas Recirculation Flow

Catalyst System Efficiency Below

Evaporative Emission Control Sys Evaporative Emission Control Sys Evaporative Emission Control Sys Evaporative Emission Control Sys Evaporative Emission Control Sys Evaporative Emission Control Sys

GD(H4SO)-4

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0456

Item Evaporative Emission Control System Leak Detected (Very Small Leak)

Index

P0457

Evaporative Emission Control System Leak Detected (Fuel Cap Loose/ Off) Evaporative Emission System Purge Control Valve Circuit Low











P0458

P0459

Evaporative Emission System Purge Control Valve Circuit High

P0461

Fuel Level Sensor “A” Circuit Range/ Performance

P0462

Fuel Level Sensor “A” Circuit Low

P0463

Fuel Level Sensor “A” Circuit High

P0464

Fuel Level Sensor Circuit Intermittent

P0500

Vehicle Speed Sensor “A”

P0506

Idle Air Control System RPM Lower Than Expected

P0507

Idle Air Control System RPM Higher Than Expected

P0512

Starter Request Circuit

P0513

Incorrect Immobilizer Key

P0604

Internal Control Module Random Access Memory (RAM) Error

P0605

Internal Control Module Read Only Memory (ROM) Error

P0607

Throttle Control System Circuit Range/Performance

P0638

Throttle Actuator Control Range/Performance (Bank 1)

P0700

Transmission Control System (MIL Request) Park/Neutral Switch Input Circuit Low (AT Model) Neutral Switch Input Circuit Low (MT Model) Park/Neutral Switch Input Circuit High (AT Model) Neutral Switch Input Circuit High (MT Model)

P0851 P0851 P0852 P0852





GD(H4SO)-5

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P1152

Item O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1)

P1153

O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1)

P1160

Return Spring Failure

P1443

Vent Control Solenoid Valve Function Problem EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input)

P1492

P1493

EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input)

P1494

EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input)

P1495

EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input)

P1496

EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input)

P1497

EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input)

P1498

EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input)

P1499

EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input)

P1518

Starter Switch Circuit Low Input

P1560

Back-Up Voltage Circuit Malfunction

P1570

Antenna

P1571

Reference Code Incompatibility

P1572

IMM Circuit Failure

P1574

Key Communication Failure

P1576

EGI Control Module EEPROM

P1577

IMM Control Module EEPROM

P1578

Meter Failure

P1602

Control Module Programming Error

P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

Index















GD(H4SO)-6

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P2097 P2101

P2102 P2103 P2109

P2122

P2123

P2127

P2128

P2135

P2138

P2227

P2228 P2229 U0073 U0101 U0122 U0140 U0402 U0416 U0422

Item Post Catalyst Fuel Trim System Too Rich (Bank 1) Throttle Actuator Control Motor Circuit Range/Performance

Index

Throttle Actuator Control Motor Circuit Throttle Actuator Control Motor Circuit High Throttle/Pedal Position Sensor “A”

Throttle/Pedal Position Sensor/Switch Throttle/Pedal Position Sensor/Switch Throttle/Pedal Position Sensor/Switch Throttle/Pedal Position Sensor/Switch Throttle/Pedal Position Sensor/Switch Throttle/Pedal Position Sensor/Switch Atmospheric Pressure Sensor Range/ Barometric Pressure Circuit Low

Barometric Pressure Circuit High

CAN Failure, Bus ‘OFF’ Detection

CAN (TCU) Data not Loaded

CAN (VDC) Data not Loaded

CAN (BCU) Data not Loaded

CAN (TCU) Data Abnormal

CAN (VDC) Data Abnormal

CAN (BCU) Data Abnormal

GD(H4SO)-7

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

2. Diagnostic Trouble Code (DTC) Detecting Criteria A: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1) 1. OUTLINE OF DIAGNOSIS Judge as NG with either Low NG or High NG. A variable valve lift diagnosis oil pressure switch is installed for diagnosis. It is possible to determine whether the intake valve is in high mode (increase the amount of lift) or in low mode (suppressing the amount of lift) when the variable valve lift diagnosis oil pressure switch is turned ON or OFF. • Normal Oil switching solenoid valve duty

Intake valve

Large Minimum

High mode Low mode

Variable valve lift diagnosis oil pressure switch OFF ON

• Low NG When the variable valve lift diagnosis oil pressure switch remains ON even though the intake valve tried to enter high mode (oil switching solenoid valve duty is large), this is judged as a Low NG. • High NG When the variable valve lift diagnosis oil pressure switch remains OFF even though the intake valve tried to enter low mode (oil switching solenoid valve duty is small), this is judged as a High NG.

2. COMPONENT DESCRIPTION The variable valve lift system optimizes the intake valve lift by switching between the low lift cam and the high lift cam according to the engine speed. The amount of intake valve lift is varied by controlling the oil switching solenoid valve duty according to signals from the ECM.

(A) (B) EN-05565

(A)

Low lift

(B)

High lift

GD(H4SO)-8

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Battery voltage After engine starting Engine oil temperature Variable valve lift control

Enable Conditions ≥ 10.9 V ≥ 6000 ms ≥ 15 °C (59 °F) Operation

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously 6 seconds after engine start while variable valve lift is being controlled.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Low Duty ratio Variable valve lift diagnosis oil pressure switch High Duty ratio Variable valve lift diagnosis oil pressure switch

Threshold Value ≥ 62 % ON

< 33 % OFF

Time Needed for Diagnosis: Low side: 784 ms High side: 3000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Low Duty ratio Variable valve lift diagnosis oil pressure switch High Duty ratio Variable valve lift diagnosis oil pressure switch

Threshold Value ≥ 62 % OFF

< 33 % ON

Time Needed for Diagnosis: Low side: 208 ms High side: 3000 ms

GD(H4SO)-9

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

B: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0026.

GD(H4SO)-10

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect functional errors of the front oxygen (A/F) sensor heater. Judge as NG when it is determined that the front oxygen (A/F) sensor impedance is large when looking at engine status such as deceleration fuel cut.

2. COMPONENT DESCRIPTION

(1)

(2)

(3)

(4)

(5)

EN-07655

(1) (2)

Element cover (outer) Element cover (inner)

(3) (4)

Sensor element Ceramic heater

(5)

Sensor housing

3. ENABLE CONDITION Secondary Parameters Condition established time Battery voltage Heater current Control duty ≥ 35 % After fuel cut

Enable Conditions ≥ 42000 ms ≥ 10.9 V Permitted Experienced ≥ 20000 ms

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after 42000 ms or more have passed since the engine started.

GD(H4SO)-11

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Front oxygen (A/F) sensor impedance

Threshold Value > 50 Ω

Time Needed for Diagnosis: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Front oxygen (A/F) sensor impedance

Threshold Value ≤ 50 Ω

Time Needed for Diagnosis: 10000 ms

GD(H4SO)-12

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

D: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect front oxygen (A/F) sensor heater open or short circuit. The front oxygen (A/F) sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains Low.

2. COMPONENT DESCRIPTION

(A) OFF (B)

(D)

ON 0V

(C)

EN-01792

(A)

Battery voltage

(D)

Low error

(B)

Front oxygen (A/F) sensor heater output voltage

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-13

(C)

128 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Front oxygen (A/F) sensor heater control duty

Threshold Value Low < 87.5 %

Time Needed for Diagnosis:4 ms × 250 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

GD(H4SO)-14

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

E: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect front oxygen (A/F) sensor heater open or short circuit. The front oxygen (A/F) sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains High.

2. COMPONENT DESCRIPTION

(A) (D)

OFF

(B)

ON 0V

(C)

EN-01793

(A)

Battery voltage

(D)

High error

(B)

Front oxygen (A/F) sensor heater output voltage

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-15

(C)

128 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Front oxygen (A/F) sensor heater control duty

Threshold Value High ≥ 12.5 %

Time Needed for Diagnosis:4 ms × 500 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value Low

Time Needed for Diagnosis: Less than 1 second

GD(H4SO)-16

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

F: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect the rear oxygen sensor heater open or short circuit. The rear oxygen sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains Low.

2. COMPONENT DESCRIPTION

(A) OFF (B)

ON

(D)

0V

(C)

EN-01792

(A)

Battery voltage

(D)

Low error

(B)

Output voltage of the rear oxygen sensor heater

(C)

256 ms (cycle)

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine Engine speed

Enable Conditions ≥ 10.9 V ≥ 1 second < 8000 rpm

4. GENERAL DRIVING CYCLE After starting the engine, perform the diagnosis continuously when engine is low speed.

GD(H4SO)-17

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Rear oxygen sensor heater control duty

Threshold Value Low < 75 %

Time Needed for Diagnosis:8 ms × 1250 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

GD(H4SO)-18

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

G: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect the rear oxygen sensor heater open or short circuit. The rear oxygen sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains High.

2. COMPONENT DESCRIPTION

(A) (D)

OFF

(B)

ON 0V

(C)

EN-01793

(A)

Battery voltage

(D)

High error

(B)

Output voltage of the rear oxygen sensor heater

(C)

256 ms (cycle)

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine Engine speed

Enable Conditions ≥ 10.9 V ≥ 1 second < 8000 rpm

4. GENERAL DRIVING CYCLE After starting the engine, perform the diagnosis continuously when engine is low speed.

GD(H4SO)-19

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Rear oxygen sensor heater control duty

Threshold Value High ≥ 20 %

Time Needed for Diagnosis:8 ms × 1250 time (s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

H: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION 1. OUTLINE OF DIAGNOSIS Detect problems in the intake manifold pressure sensor output properties. Judge as NG when the intake air pressure AD value is Low whereas it seemed to be High from the viewpoint of engine condition, or when it is High whereas it seemed to be Low from the engine condition.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(B)

(3)

EN-01765

(A)

Output voltage

(B)

Absolute pressure

(1)

Connector

(2)

Terminals

3. ENABLE CONDITION Secondary Parameters Engine coolant temperature

Enable Conditions ≥ 60 °C (140 °F)

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after idling.

GD(H4SO)-21

(3)

O-ring

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when Low side or High side becomes NG. If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load

Threshold Value < 2500 rpm ≥ 12 ° < 1.46 V > 0.5 g/rev (0.02 oz/rev) 600 rpm — 900 rpm < 4.4 ° ≥ 2.5 V < 0.4 g/rev (0.01 oz/rev)

Time Needed for Diagnosis: Low side: 5000 ms High side: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG when both Low side and High side become OK. If the duration of time while the following conditions are met is longer than the time indicated, judge as OK. Judgment Value Malfunction Criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load

Threshold Value < 2500 rpm ≥ 12 ° ≥ 1.46 V > 0.5 g/rev (0.02 oz/rev) 600 rpm — 900 rpm < 4.4 ° < 2.5 V < 0.4 g/rev (0.01 oz/rev)

Time Needed for Diagnosis: Low side: Less than 1 s High side: Less than 1 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

I:

DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)

1. OUTLINE OF DIAGNOSIS Detect the open circuit of the oil switching solenoid valve. Judge as NG when the current is small even though the output duty is large.

2. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Duty ratio Control current

Threshold Value ≥ 30 % < 0.026 A

Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria |Oil switching solenoid valve target current value – Oil switching solenoid valve current value| Target current

Threshold Value < 0.08 A

≥ 0.11 A

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

J: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect short circuits of the oil switching solenoid valve. Judge as a short NG when the current is large even though the output duty is small.

2. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Duty ratio Control current

Threshold Value 0.22 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

O: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect open or short circuits of the air flow sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3) (2)

(A)

(4)

EN-01766

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Voltage (V)

(4)

Amount of intake air (kg (lb)/s)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.19 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.19 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

P: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of intake manifold pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(B)

(3)

EN-01765

(A)

Output voltage

(B)

Absolute pressure

(1)

Connector

(2)

Terminals

(3)

O-ring

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≤ 0.573 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value > 0.573 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Q: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of intake manifold pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(B)

(3)

EN-01765

(A)

Output voltage

(B)

Absolute pressure

(1)

Connector

(2)

Terminals

(3)

O-ring

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.388 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.388 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

R: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect the malfunction of intake air temperature sensor output property. Judge as NG when the intake air temperature is not varied whereas it seemed to be varied from the viewpoint of engine condition.

2. COMPONENT DESCRIPTION

(1)

(3)

(2) (A) (4)

EN-01767

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Resistance value (Ω)

3. ENABLE CONDITION Secondary Parameters Engine coolant temperature at engine starting Battery voltage Continuous time when the vehicle speed is less than 140 km/h (87 MPH) Engine coolant temperature Intake air amount sum value

Enable Conditions < 35 °C (95 °F)

Number of experiences under conditions below • Continuous time when vehicle speed is less than 4 km/h (2.5 MPH) • Continuous time when vehicle speed is 40 km/h (24.9 MPH) or more and Establishing time of 1, 2 1. Intake air amount 2. Vehicle speed

≥ 3 time(s)

≥ 10.9 V ≥ 600 s ≥ 75 °C (167 °F) ≥ Value of Map 1

≥ Value from Map 2 ≥ 15 s

≥ 15 s ≥ 10 g/s (0.35 oz/s) ≥ 4 km/h (2.5 MPH)

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(4)

Intake air temperature °C (°F)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Map 1 Engine coolant temperature °C (°F) Intake air amount sum value (g (oz)/s)

–20 (–4) 50000 (1763.5)

–10 (14) 7400 (261)

0 (32) 6600 (232.78)

10 (50) 5800 (204.57)

–30 (–22)

0 (32)

10 (50)

20 (68)

250

40

32

24

20 (68) 4500 (158.72)

Map 2 Engine coolant temperature °C (°F) Continuous time (s) when vehicle speed is less than 4 km/h (2.5 MPH)

4. GENERAL DRIVING CYCLE Perform the diagnosis when the vehicle speed condition is met after warming up from a cold condition.

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Output voltage difference between Max. and Min.

Threshold Value < 0.02 V(Equivalent to approximately 0.5°C (0.9°F) near 25°C)

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Output voltage difference between Max. and Min.

Threshold Value ≥ 0.02 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

S: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the intake air temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3)

(2) (A) (4)

EN-01767

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Resistance value (Ω)

(4)

Intake air temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.231 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.231 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

T: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the intake air temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3)

(2) (A) (4)

EN-01767

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Resistance value (Ω)

(4)

Intake air temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.716 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.716 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

U: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the engine coolant temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.275 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.275 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

V: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the engine coolant temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.716 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.716 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

W: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value ≤ 0.217 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value > 0.217 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

X: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value ≥ 4.858 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value < 4.858 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Y: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL 1. OUTLINE OF DIAGNOSIS Detect the malfunction of engine coolant temperature output property. Judge as NG when the engine coolant temperature does not rise in driving conditions where it should.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters Engine speed Battery voltage

Enable Conditions ≥ Value from Map ≥ 10.9 V

Map Engine coolant temperature °C (°F) Engine speed rpm

–40 (–40)

–30 (–22)

–20 (–4)

–10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

500

500

500

500

500

500

500

500

Engine coolant temperature °C (°F) Engine speed rpm

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100 (212)

110 (230)

500

500

500

500

500

500

500

500

4. GENERAL DRIVING CYCLE Perform the diagnosis only once after engine start.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG if the criteria below are met. Judgment Value Malfunction Criteria Engine coolant temperature Timer for diagnosis after engine start

Threshold Value < 20 °C (68 °F) ≥ Judgment value of timer after engine start

Timer for diagnosis after engine start a. Timer stop at fuel cut b. During the driving conditions except a) above, timer counts up as follows. 64 ms + TWCNT ms (at 64 ms) TWCNT is defined as follows, TWCNT = 0 at idle switch ON, TWCNT show on the following table at idle switch OFF.

Temperature °C (°F)

–20 (–4) –10 (14) 0 (32) 10 (50) 20 (68)

0 (0)

8 (5)

16 (9.9)

0 ms 0 ms 0 ms 0 ms 0 ms

32.076 ms 25.704 ms 17.646 ms 7.901 ms 7.901 ms

39.977 ms 33.606 ms 25.548 ms 15.802 ms 15.802 ms

Vehicle speed km/h (MPH) 24 (14.9) 32 (19.9) 40 (24.9) 47.879 ms 41.508 ms 33.45 ms 23.704 ms 23.704 ms

82.544 ms 68.52 ms 53.652 ms 37.941 ms 37.941 ms

117.209 ms 95.532 ms 73.855 ms 52.177 ms 52.177 ms

48 (29.8)

56 (34.8)

154.214 ms 125.667 ms 97.12 ms 68.573 ms 68.573 ms

185.26 ms 155.802 ms 120.386 ms 82.538 ms 82.538 ms

Judgment value of timer after engine starting t = 573669 ms – 33924 ms × Ti Ti : The lowest coolant temperature after engine start Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Engine coolant temperature

Threshold Value ≥ 20 °C (68 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Z: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION 1. OUTLINE OF DIAGNOSIS Detect the malfunction of the engine coolant temperature sensor characteristics. Memorize the engine coolant temperature and fuel temperature at the last engine stop, and use them to judge as NG when the engine coolant temperature does not decrease when it should.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters Battery voltage Refueling from the last engine stop till the current engine start Fuel level Engine coolant temperature at the last engine stop

Enable Conditions ≥ 10.9 V None ≥ 15 2 (3.96 US gal, 3.3 Imp gal) ≥ 75 °C (167 °F)

4. GENERAL DRIVING CYCLE Perform the diagnosis only once after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Engine coolant temperature at the last engine stop — Minimum engine coolant temperature after the engine start Fuel temperature at the last engine stop — fuel temperature Intake air temperature — fuel temperature Fuel temperature

Threshold Value < 2.5 °C (36.5 °F)

≥ 5 °C (41 °F) < 2.5 °C (36.5 °F) < 35 °C (95 °F)

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Engine coolant temperature at the last engine stop — Minimum engine coolant temperature after the engine start

Threshold Value ≥ 2.5 °C (36.5 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AA:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE) 1. OUTLINE OF DIAGNOSIS Detect malfunctions of the thermostat function. Judge as NG when the engine coolant temperature is lower than the estimated engine coolant temperature and the difference between them is large. Judge as OK when the engine coolant temperature becomes to 75°C (167°F), and the difference is small, before judging NG.

2. COMPONENT DESCRIPTION (8)

(2)

(2)

(7)

(6)

(5)

(4)

(9)

(1) (3) EN-01692

(1) (2) (3)

Valve Spring Stopper

(4) (5) (6)

Piston Guide Rubber seal

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-43

(7) (8) (9)

Stop ring Wax element Jiggle valve

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Estimate ambient temperature Thermostat malfunction diagnosis Engine coolant temperature at engine starting Estimated coolant temperature Engine coolant temperature (Estimated – Measured) Engine coolant temperature Vehicle speed

Threshold Value ≥ 10.9 V ≥ –7 °C (19.4 °F) Incomplete < 55 °C (131 °F) ≥ 77 °C (170.6 °F) ≤ 77 °C (170.6 °F) > 30 °C (86 °F) ≥ 30 km/h (18.6 MPH)

Time Needed for Diagnosis:64 ms × 3 time(s) × 152 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Estimate ambient temperature Thermostat malfunction diagnosis Engine coolant temperature at engine starting Engine coolant temperature (Estimated – Measured) Engine coolant temperature

Threshold Value ≥ 10.9 V ≥ –7 °C (19.4 °F) Incomplete < 55 °C (131 °F) ≥ 77 °C (170.6 °F) ≤ 30 °C (86 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AB:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of sensor. Judge as NG, when the element voltage is out of the specified range.

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Input voltage (+) or Input voltage (–) or |Input voltage (+) – Input voltage (–)|

Threshold Value < 1.128 V < 0.23 V < 0.644 V

Time Needed for Diagnosis: Input voltage (+): 1000 ms Input voltage (–): 1000 ms |Input voltage (+) – Input voltage (–)|: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Input voltage (+) Input voltage (–) |Input voltage (+) – Input voltage (–)|

Threshold Value ≥ 1.128 V ≥ 0.23 V ≥ 0.644 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AC:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of sensor. Judge as NG, when the element voltage is out of the specified range.

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Input voltage (+) or Input voltage (–)

Threshold Value > 3.589 V > 3.541 V

Time Needed for Diagnosis: Input voltage (+): 1000 ms Input voltage (–): 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Input voltage (+) Input voltage (–)

Threshold Value ≤ 3.589 V ≤ 3.541 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AD:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect the slow response of front oxygen (A/F) sensor. Front oxygen (A/F) sensor cover has some ventilation holes for exhaust gas. Clogged ventilation holes are diagnosed. When the holes are clogged, the A/F output variation becomes slow comparing with the actual A/F variation because oxygen which reaches the zirconia layer is insufficient. Therefore, if the sensor cover holes are clogged, the rich to lean judgment in the ECM is delayed when the actual change from rich to lean occurs. Judge as NG when the actual movement in comparison to the ECM control amount is slow.

(2)

(3)

(1) EN-01694

(1)

Cover

(2)

Zirconia

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(3)

Clogging

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Barometric pressure Closed loop control with main feedback Front oxygen (A/F) sensor impedance Elapsed time after starting the engine Engine coolant temperature Engine speed Vehicle speed Amount of intake air Engine load Learning value of EVAP conc. during purge Total time of operating canister purge

Enable Conditions ≥ 1024 ms ≥ 10.9 V > 75 kPa (563 mmHg, 22.2 inHg) Operation 0 Ω — 50 Ω ≥ 120000 ms ≥ 75 °C (167 °F) 1000 rpm — 3200 rpm 10 km/h — 120 km/h (6.2 MPH — 74.6 MPH) 10 g/s — 40 g/s (0.35 oz/s — 1.41 oz/s) < 0.02 g/rev (0 oz/rev) < 0.2 ≥ 19.9 s

4. GENERAL DRIVING CYCLE Perform diagnosis only once at a constant speed of 10 km/h — 120 km/h (6.2 MPH — 74.6 MPH) 120000 ms or more after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD Calculate faf difference every 32 ms × 4 , and the λ value difference. Calculate the diagnosis value after calculating 820 time(s). • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria parafca = td2faf/td2lmd where, td2faf (N) = td2faf (n–1) + |d2faf (n)| td2lmd (N) = td2lmd (n–1) + |d2lmd (n)| add up to 32 ms × 4 × 820 time(s). d2faf (n) = (faf (n) – faf (n–1)) – (faf (n–1) – faf (n–2)) d2lmd (n) = (lmd (n) – lmd (n–1)) – (lmd (n–1) – lmd (n–2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds

Threshold Value > 0.3

Time Needed for Diagnosis: 32 ms × 4 × 820 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria parafca = td2faf/td2lmd

Threshold Value ≤ 0.3

where, td2faf (N) = td2faf (n–1) + |d2faf (n)| td2lmd (N) = td2lmd (n–1) + |d2lmd (n)| add up to 32 ms × 4 × 820 time(s). d2faf (n) = (faf (n) – faf (n–1)) – (faf (n–1) – faf (n–2)) d2lmd (n) = (lmd (n) – lmd (n–1)) – (lmd (n–1) – lmd (n–2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds

Time Needed for Diagnosis: 32 ms × 4 × 820 time(s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AE:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect open circuits of the sensor. Judge as NG when the impedance of the element is large.

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Time of heater control duty at 70 % or more Front oxygen (A/F) sensor impedance.

Threshold Value ≥ 10.9 V ≥ 36000 ms > 500 Ω

Time Needed for Diagnosis: 5000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Front oxygen (A/F) sensor impedance.

Threshold Value ≥ 10.9 V ≤ 500 Ω

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AF:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect continuity NG of the oxygen sensor. If the oxygen sensor voltage reading is not within the probable range considering the operating conditions, judge as NG.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Used for abnormality judgment Secondary Parameters High Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Low (1) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Low (2) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Current continuation time of the rear oxygen sensor heater Low (3) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Current continuation time of the rear oxygen sensor heater Fuel cut

Enable Conditions Not in operation In operation < 5 time(s) Not in limit value ≥ 10.9 V ≥ 75 °C (167 °F) Not in operation In operation < 5 time(s) Not in limit value ≥ 10.9 V ≥ 75 °C (167 °F) ≥ 10 g/s (0.35 oz/s) Not in operation In operation < 5 time(s) Not in limit value ≥ 10.9 V ≥ 75 °C (167 °F) < 10 g/s (0.35 oz/s) ≥ 30000 ms

Not in operation In operation < 5 time(s) Not in limit value ≥ 10.9 V ≥ 75 °C (167 °F) < 10 g/s (0.35 oz/s) ≥ 30000 ms Experienced

Used for normality judgment Secondary Parameters Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature

Enable Conditions Not in operation In operation < 5 time(s) Not in limit value ≥ 10.9 V ≥ 75 °C (167 °F)

4. GENERAL DRIVING CYCLE After starting the engine, continuously perform the diagnosis with the same engine condition.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria High Sensor output voltage Low Sensor output voltage

Threshold Value

DTC P0138

> 1.2 V P0137 < 0.03 V

Time Needed for Diagnosis: High: 2500 ms Low (1): 20000 ms Low (2): 40000 ms Low (3): Value from Map Map Fuel cut time (ms) Time Needed for Diagnosis (ms)

0 40000

2000 40000

10000 60000

Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria High Sensor output voltage Low Sensor output voltage

Threshold Value

DTC P0138

≤ 1.2 V P0137 ≥ 0.03 V

Time Needed for Diagnosis: High: Less than 1 s Low (1): Less than 1 s Low (2): Less than 1 s Low (3): Less than 1 s

AG:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0137.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AH:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect the slow response of the oxygen sensor. Judge as NG if either the rich to lean response diagnosis or lean to rich response diagnosis is NG, and Judge as OK if both are OK. [Rich → lean diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to rich to lean. If the measured response time is larger than the threshold value, it is NG. If it is smaller, it is OK. Response time calculation is categorized in two by voltage difference. • Response time in small voltage difference: Intermediate • Response time in large voltage difference: Wide 2. Judge as NG when the oxygen sensor voltage is large (rich) even after deceleration fuel cut has occurred. [Lean → rich diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to lean to rich. If the measured response time is larger than the threshold value, it is NG. 2. Judge as NG when the oxygen sensor voltage remains small when recovering from a deceleration fuel cut. Diagnostic method Measure the response time of the output change of the oxygen sensor when the A/F ratio changes to rich to lean. And Judge as NG when the measured response time is larger than the threshold value.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Rich → lean diagnosis response Secondary Parameters Battery voltage A/F main feedback control condition Deceleration fuel cut time of 5000 ms or more (intermediate) Deceleration fuel cut time of 5000 ms or more (wide) After fuel cut

Estimated temperature of the rear oxygen sensor element

Number of deceleration fuel cut

Enable Conditions ≥ 10.9 V Complete Experienced

≥ 2000 ms (Intermediate) ≥ 2000 ms (Wide) ≥ 500 °C (932 °F) (Intermediate) ≥ 500 °C (932 °F) (Wide) ≥ 1 time(s)

4. GENERAL DRIVING CYCLE Perform diagnosis once during deceleration fuel cut from a constant and high speed driving, when rear oxygen sensor is warmed up sufficiently. (Pay attention to the oxygen sensor voltage for the timing of the deceleration.)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Intermediate When the oxygen sensor output voltage changes from 0.55 V (rich) to 0.15 V (lean), calculate the minimum response time for output change between 0.5 V and 0.2 V for the judgment criteria.

Diagnosis execution condition

(A) (B)

Rear oxygen sensor (V) (G) (C) (D) (E)

Fuel cut on deceleration (F) (H)

EN-05566

(A) (D) (G)

0.55 V 0.15 V Measure the response time.

(B) (E) (H)

0.5 V 0V Execute the malfunction judgment in 2000 ms from the recovery of fuel cut on deceleration.

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(C) (F)

0.2 V More than 5000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Wide When the oxygen sensor output voltage changes from 0.65 V (rich) to 0.05 V (lean), calculate the minimum response time for output change between 0.6 V and 0.1 V for the judgment criteria.

Diagnosis execution condition

(A) (B)

Rear oxygen sensor (V) (G) (C) (D) (E)

Fuel cut on deceleration (F) (H)

EN-05566

(A)

0.65 V

(B)

0.6 V

(C)

0.1 V

(D) (G)

0.05 V Measure the response time.

(E) (H)

0V Execute the malfunction judgment in 2000 ms from the recovery of fuel cut on deceleration.

(F)

More than 5000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment 1) Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut. Response time (diagnosis value) > threshold value → abnormal NOTE: Perform NG judgment only during fuel cut, when exhaust gas apparently changes from rich → lean. Even without deceleration fuel cut, judge as OK if the value is below the threshold. 2) Judge as NG when the oxygen sensor voltage at a deceleration fuel cut is large. Judge as NG when oxygen sensor voltage is large even after a long period of deceleration fuel cut has completed. Judgment value (Intermediate) Malfunction Criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V or Longest time over 0.55 V

Threshold Value > 491 ms

≥ 2000 ms

Judgment value (Wide) Malfunction Criteria Shortest time change from rich (0.6 V O2 output) to lean (0.1 V) when voltage reduces from 0.65 V to 0.05 V or Longest time over 0.65 V

Threshold Value > Value from Map

≥ 2000 ms

Map Estimated temperature of rear oxygen sensor element when fuel cut starts °C (°F)

0 (32)

450 (842)

500 (932)

1000 (1832)

Longest time in rich status after fuel cut (ms)

2000

2000

2000

2000

Time Needed for Diagnosis: 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment 1) Regardless of a deceleration fuel cut, if the response time (diagnosis value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as a normal condition. Response time (diagnosis value) ≤ threshold value → normal 2) Do not judge as a normal condition. Judge as OK and clear the NG if the following conditions are established.

Judgment value (Intermediate) Malfunction Criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V

Threshold Value ≤ 491 ms

Judgment value (Wide) Malfunction Criteria Shortest time change from rich (0.6 V O2 output) to lean (0.1 V) when voltage reduces from 0.65 V to 0.05 V

Threshold Value ≤ 2000 ms

Time Needed for Diagnosis: 1 time(s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

6. ENABLE CONDITION Lean → rich response diagnosis Secondary Parameters Battery voltage A/F main feedback control condition Deceleration fuel cut time is 6000 ms or more. After fuel cut Number of deceleration fuel cut

Enable Conditions ≥ 10.9 V Complete Experienced ≥ 2000 ms ≥ 1 time(s)

7. GENERAL DRIVING CYCLE Perform diagnosis once during deceleration fuel cut from a constant and high speed driving, when rear oxygen sensor is warmed up sufficiently. (Pay attention to the oxygen sensor voltage for the timing of the deceleration.)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

8. DIAGNOSTIC METHOD When the oxygen sensor output voltage changes from 0.25 V (lean) to 0.55 V (rich), calculate the minimum response time for output change between 0.3 V and 0.5 V for the judgment criteria.

Diagnosis execution condition

(H)

(A) (B)

Rear oxygen sensor (V)

(C) (D) (E)

(J)

(G) Fuel cut on deceleration (F) (I)

EN-05567

(A) (D) (G)

0.55 V 0.25 V More than 120000 ms

(J)

Judge NG when the voltage of rear oxygen sensor is 0.25 V or less for 120000 ms or more after recovery of fuel cut on deceleration.

(B) (E) (H)

0.5 V 0V Measure the response time (diagnostic value).

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(C) (F) (I)

0.3 V More than 5 seconds Execute the malfunction judgment in 4000 ms from the recovery of fuel cut on deceleration.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment 1) Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut. Response time (diagnosis value) > threshold value → abnormal 2) If the oxygen sensor voltage is small after recovering from a deceleration fuel cut, and remains small, judge as NG. Judgment Value Malfunction Criteria Shortest time change from lean (0.3 V O2 output) to rich (0.5 V) when voltage changes from 0.25 V to 0.55 V or Longest time under 0.25 V

Threshold Value > 4000 ms

≥ 120000 ms

Time Needed for Diagnosis: 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment 1) Regardless of a deceleration fuel cut, if the response time (diagnosis value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as a normal condition. Response time (diagnosis value) ≤ threshold value → normal 2) Do not judge as a normal condition. Judge as OK and clear the NG if the following conditions are established.

Judgment Value Malfunction Criteria Shortest time change from lean (0.3 V O2 output) to rich (0.5 V) when voltage changes from 0.25 V to 0.55 V

Threshold Value ≤ 4000 ms

Time Needed for Diagnosis: 1 time(s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AI: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2) 1. OUTLINE OF DIAGNOSIS Detect the rear oxygen sensor open or short circuit. Judge as NG when the rear oxygen sensor voltage can be determined to be abnormal considering conditions such as intake air amount, engine coolant temperature, main feedback control and deceleration fuel cut.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

3. ENABLE CONDITION (USED ONLY FOR MALFUNCTION JUDGMENT) Secondary Parameters Closed loop control at the rear oxygen sensor Target output voltage of rear oxygen sensor Amount of intake air Engine coolant temperature Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Deceleration fuel cut of 5000 ms or more.

Enable Conditions In operation ≥ 0.55 V + 0.05 V ≥ 10 g/s (0.35 oz/s) ≥ 75 °C (167 °F) < 5 time(s) Not in limit value ≥ 10.9 V Experienced

4. GENERAL DRIVING CYCLE Perform the diagnosis once after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Minimum output voltage or Maximum output voltage

Threshold Value > 0.15 V < 0.55 V

Time Needed for Diagnosis: 200000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Threshold Value Diagnosis of the rear oxygen sensor volt- Incomplete age low side Minimum output voltage ≤ 0.15 V Maximum output voltage ≥ 0.55 V

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AJ:DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of rear oxygen sensor heater. While observing the engine condition, judge as NG if the rear oxygen sensor impedance is great.

2. COMPONENT DESCRIPTION

(1)

(2)

(3)

(4)

(5)

EN-07655

(1) (2)

Element cover (outer) Element cover (inner)

(3) (4)

Sensor element Ceramic heater

(5)

Sensor housing

3. ENABLE CONDITIONS Secondary Parameters Battery voltage Elapsed time after starting the engine Engine coolant temperature A/F sensor element impedance A/F sensor heater control duty Rear oxygen sensor heater control duty

Enable Conditions ≥ 10.9 V ≥ 1000 ms ≥ 75 °C (167 °F) ≤ 50 Ω ≤ 75 % < 70 %

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after 1000 ms seconds or more have passed since the engine started.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output terminal for heater characteristics fault detection

Threshold Value Low

Time Needed for Diagnosis: 4 ms × 2500 time (s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output terminal for heater characteristics fault detection

Threshold Value High

Time Needed for Diagnosis: 4 ms × 2500 time (s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AK:DTC P0171 SYSTEM TOO LEAN (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect fuel system malfunction by the amount of main feedback control. Diagnostic method Fuel system is diagnosed by comparing the target air fuel ratio calculated by ECM with the actual air fuel ratio measured by sensor.

2. ENABLE CONDITION Secondary Parameters A/F main learning system Engine coolant temperature Engine load change Engine load

Enable Conditions In operation ≥ 75 °C (167 °F) < 0.02 g/rev (0 oz/rev) ≥ Value of Map 1

Map 1 Engine speed (rpm)

Idling

650

1000

1500

2000

2500

3000

3500

4000

4500

na

0.208 (0.01)

0.201 (0.01)

0.185 (0.01)

0.183 (0.01)

0.193 (0.01)

0.206 (0.01)

0.206 (0.01)

0.225 (0.01)

0.245 (0.01)

Measured value (g (oz)/rev)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment Compare the diagnosed value (fsobd) with the threshold value, and if a condition meeting the malfunction criteria below continues for 10 s × 5 time(s) or more, judge that there is a fault in the fuel system. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf In this case: sglmd = measured lambda

Threshold Value ≥ Value from Map 2

tglmda = target lambda faf = Main feedback compensation coefficient (every 64 ms) flaf = main feedback learning compensation coefficient

Map 2 Amount of air (g (oz)/s) fsobdL1 (%)

0 (0) 1.4

3.2 (0.11) 1.4

6.4 (0.23) 1.332

9.6 (0.34) 1.25

12.8 (0.45) 1.25

16 (0.56) 1.25

19.2 (0.68) 1.25

Time Needed for Diagnosis: 10 s × 5 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf

Threshold Value < 1.2

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AL:DTC P0172 SYSTEM TOO RICH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect fuel system malfunction by the amount of main feedback control. Diagnostic method Fuel system is diagnosed by comparing the target air fuel ratio calculated by ECM with the actual air fuel ratio measured by sensor.

2. ENABLE CONDITION Secondary Parameters A/F main learning system Engine coolant temperature Engine load change Learning value of EVAP conc. Cumulative time of canister purge after engine start Continuous period after canister purge starting Engine load

Enable Conditions In operation ≥ 75 °C (167 °F) ≤ 0.02 g/rev (0 oz/rev) < 0.15 ≥ 20 s ≥ 29884 ms ≥ Value of Map 1

Map 1 Engine speed (rpm)

Idling

650

1000

1500

2000

2500

3000

3500

4000

4500

na

0.208 (0.01)

0.201 (0.01)

0.185 (0.01)

0.183 (0.01)

0.193 (0.01)

0.206 (0.01)

0.206 (0.01)

0.225 (0.01)

0.245 (0.01)

Measured value (g (oz)/rev)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment Compare the diagnosed value (fsobd) with the threshold value, and if a condition meeting the malfunction criteria below continues for 10 s × 5 time(s) or more, judge that there is a fault in the fuel system. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf In this case: sglmd = measured lambda tglmda = target lambda faf = Main feedback compensation coefficient (every 64 ms) flaf = main feedback learning compensation coefficient

Threshold Value < Value of Map 2

Map 2 Amount of air (g (oz)/s) fsobdL1 (%)

0 (0) 0.6

3.2 (0.11) 0.6

6.4 (0.23) 0.668

9.6 (0.34) 0.735

12.8 (0.45) 0.735

16 (0.56) 0.735

19.2 (0.68) 0.735

Time Needed for Diagnosis: 10 s × 5 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK when the malfunction criteria below are met for 10 seconds. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf

Threshold Value ≥ 0.8

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AM:DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect faults in the fuel temperature sensor output properties. Diagnosis is performed in two methods (drift diagnosis and stuck diagnosis). If either is NG, judge as NG. If both are OK, Judge as OK and clear the NG. Drift Diagnosis Normally fuel temperature is lower than engine coolant temperature. When the fuel temperature becomes higher than the engine coolant temperature, the range is considered to be shifted, and judged as NG. Stuck Diagnosis As the engine warms up (cumulative amount of intake air after starting is large), if the fuel temperature which should rise does not, determine as being stuck and NG.

2. COMPONENT DESCRIPTION

(A)

(B)

EN-01700

(A)

Resistance value (Ω)

(B)

Fuel temperature °C (°F)

3. ENABLE CONDITION DRIFT DIAGNOSIS Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Fuel level Elapsed time after starting the engine Engine coolant temperature – Engine coolant temperature at engine start Fuel temperature – Engine coolant temperature Battery voltage

Threshold Value ≥ 9.6 2 (2.54 US gal, 2.11 Imp gal) ≥ 20 s > 10 °C (50 °F) ≥ 10 °C (50 °F) ≥ 10.9 V

Time Needed for Diagnosis: 120 s Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Fuel level Elapsed time after starting the engine Engine coolant temperature – Engine coolant temperature at engine start Fuel temperature – Engine coolant temperature Battery voltage Engine coolant temperature

Threshold Value ≥ 9.6 2 (2.54 US gal, 2.11 Imp gal) ≥ 20 s > 10 °C (50 °F) < 10 °C (50 °F) ≥ 10.9 V < 75 °C (167 °F)

Time Needed for Diagnosis: Less than 1 second

6. ENABLE CONDITION Stuck Diagnosis Secondary Parameters Elapsed time after starting the engine Battery voltage

Enable Conditions ≥ 20000 ms ≥ 10.9 V

7. GENERAL DRIVING CYCLE Perform the diagnosis continuously 20 seconds after starting engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

8. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Accumulated amount of intake air Fuel temperature difference between Max. and Min.

Threshold Value ≥ 551043 g (19435.29 oz) < 2 °C (35.6 °F)

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Fuel temperature difference between Max. and Min.

Threshold Value ≥ 2 °C (35.6 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AN:DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A)

(B)

EN-01700

(A)

Resistance value (Ω)

(B)

Fuel temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value < 0.573 V ≥ 10.9 V

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value ≥ 0.573 V ≥ 10.9 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AO:DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A)

(B)

EN-01700

(A)

Resistance value (Ω)

(B)

Fuel temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value ≥ 4.716 V ≥ 10.9 V

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value < 4.716 V ≥ 10.9 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AP:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect for abnormal values in the oil temperature sensor output properties. Judge as NG when the oil temperature does not rise even though the engine is running under a condition where it should rise.

2. ENABLE CONDITION Secondary Parameters Battery voltage Engine speed

Enable Conditions ≥ 10.9 V ≥ Value from Map

Map Engine coolant temperature °C (°F) Engine speed rpm

–40 (–40)

–30 (–22)

–20 (–4)

–10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

500

500

500

500

500

500

500

500

Engine coolant temperature °C (°F) Engine speed rpm

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100 (212)

110 (230)

500

500

500

500

500

500

500

500

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Engine oil temperature After engine start oil temperature sensor characteristic diagnosis timer.

Threshold Value < 15 °C (59 °F) ≥ Judgment value for after engine start oil temperature sensor characteristic diagnosis timer

After engine start oil temperature sensor characteristic diagnosis timer (timer for diagnosis). a. Timer stop at fuel cut b. During the driving conditions except a) above, timer counts up as follows. 64 ms + TOILCNT ms (at 64 ms) Where, TOILCNT is determined as follows, TOILCNT = 0 at idle switch ON For TOILCNT at Idle switch off, refer to the following table.

Temperature °C (°F)

0 (0) –30 (–22) 64 ms –20 (–4) 64 ms –10 (14) 64 ms 0 (32) 64 ms 10 (50) 102.2 ms

8 (5) 73.2 ms 73.3 ms 73.4 ms 73.5 ms 114.8 ms

16 (9.9) 83.9 ms 84 ms 84.2 ms 84.5 ms 129.4 ms

Vehicle speed km/h (MPH) 24 (14.9) 32 (19.9) 96.3 ms 113.2 ms 96.6 ms 113.7 ms 96.9 ms 114.5 ms 97.4 ms 115.6 ms 146.7 ms 171.7 ms

40 (24.9) 133.9 ms 135 ms 136.4 ms 138.5 ms 203.4 ms

48 (29.8) 160.2 ms 162 ms 164.4 ms 168 ms 245.1 ms

56 (34.8) 194.6 ms 197.4 ms 201.5 ms 207.6 ms 302.1 ms

After engine start oil temperature characteristic diagnosis timer judgment value (t). t = 1882940 ms – 43302 ms × Ti (t ≥ 2400000) Ti = The lowest coolant temperature after starting the engine. Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Engine oil temperature

Threshold Value ≥ 15 °C (59 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AQ:DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the oil temperature sensor. Judge as NG when outside of the judgment value.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.166 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.166 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AR:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the oil temperature sensor. Judge as NG when outside of the judgment value.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.716 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.716 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AS:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value ≤ 0.926 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value > 0.926 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AT:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value ≥ 4.858 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value < 4.858 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AU:DTC P0301 CYLINDER 1 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS Detect the presence of misfire occurrence. (Revolution fluctuation method) Monitoring Misfire which influences exhaust deterioration (1.5 times of FTP) and catalyst damage is made obligatory by the law. Misfire affecting these two has two patterns below. : • Intermittent misfire (The same cylinder misfires in random, or different cylinders misfire in random.) : FTP 1.5 times misfire • Every time misfire (The same cylinder misfires every time.) : FTP 1.5 times misfire, Catalyst damage misfire The following detecting methods are adopted for these detection. 1) Intermittent misfire: FTP 1.5 times misfire • 180° Interval Difference Method (MT: 1,800 rpm or less; AT: None) • 360° Interval Difference Method (whole range) • 720° Interval Difference Method (3,000 rpm or more) 2) Misfire every time: FTP 1.5 times misfire, Catalyst damage misfire • 360° Interval Difference Method

2. ENABLE CONDITION Secondary Parameters All secondary parameters enable conditions Intake manifold pressure change at 180° CA Throttle position variation for 16 ms Fuel shut-off function Fuel level Vehicle dynamic control or AT torque control Evaporative system leak check Engine speed Intake manifold pressure Battery voltage Fuel parameter determination Elapsed time after starting the engine Engine speed variation for 32 ms

Enable Conditions ≥ 1024 ms < Value of Map 1 < 21 ° Not in operation ≥ 9.6 2 (2.54 US gal, 2.11 Imp gal) Not in operation Not in operation 500 rpm — 6300 rpm ≥ Value from Map 2 ≥8V Not extremely low volatility ≥ 0 ms < 1000 rpm

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Map 1 • AT model rpm kPa (mmHg, inHg)

700 13.3 (100, 3.9)

1000 13.3 (100, 3.9)

1500 13.3 (100, 3.9)

2000 13.3 (100, 3.9)

2500 13.3 (100, 3.9)

3000 13.3 (100, 3.9)

3500 13.3 (100, 3.9)

4000 13.3 (100, 3.9)

4500 13.3 (100, 3.9)

5000 13.3 (100, 3.9)

5500 13.3 (100, 3.9)

6000 13.3 (100, 3.9)

6300 13.3 (100, 3.9)

650

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6300

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

• MT model rpm kPa (mmHg, inHg)

Map 2 • AT model rpm kPa (mmHg, inHg)

700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300 36 37.9 40 34.1 29.7 32.3 25.6 22.9 23.2 23.9 23.6 26.8 27.6 (207.0 , (192.0 , (172.0 , (174.0 , (179.0 , (177.0 , (201.0 , (223.0 , (242.0 , (256.0 , (270.0 , (284.0 , (300.0 , 10.1) 10.6) 11.2) 11.8) 7) 7) 7.9) 8.8) 9.5) 8.1) 7.6) 6.8) 6.9)

• MT model Vehicle speed < 64 km/h (39.8 MPH) rpm kPa (mmHg, inHg)

650 24.5 (184, 7.2)

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

22.7 21.4 21.5 21.5 23.2 24.7 25.8 27.1 28.8 32.3 (170.3, (160.2, (161.6, (161.4, (174.4, (185.5, (193.3, (203.2, (216.3, (242.2, 6.7) 6.3) 6.4) 6.4) 6.9) 7.3) 7.6) 8) 8.5) 9.5)

6000

6300

36.3 (272, 10.7)

37.9 (284.5, 11.2)

Vehicle speed ≥ 68 km/h (42.3 MPH) rpm kPa (mmHg, inHg)

650

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6300

31.6 (237, 9.3)

31.6 (237, 9.3)

31.6 (237, 9.3)

31.1 (233, 9.2)

31.3 (235, 9.3)

33.1 (248, 9.8)

33.9 (254, 10)

28.8 (216, 8.5)

30.1 (226, 8.9)

33.3 (250, 9.8)

36.9 (277, 10.9)

40.1 (301, 11.9)

43.2 (324, 12.8)

3. GENERAL DRIVING CYCLE • If conditions are met, it is possible to detect the misfires from idling to high engine speed. However, to avoid excessive load or harm to the engine, perform diagnosis at idle. • Perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. DIAGNOSTIC METHOD When a misfire occurs, the engine speed will decreased and the crankshaft position speed will change. Calculate the interval difference value (diagnostic value) from crankshaft position speed by the following formula, and judge whether a misfire is occurring or not comparing the calculated result with judgment value. Counting the number of misfires. If the misfire ratio is higher during 1000 revs. or 200 revs., Judge corresponding cylinders as NG. Diagnostic value calculation (Calculate from angle speed) →

Misfire detection every single ignition NG judgment (Misfire occurrence judg(Compare diagnostic value with judg- ment required by the law) (Compare ment value) → number of misfire with judgment) • 180° Interval Difference Method • 360° Interval Difference Method • 720° Interval Difference Method

• FTP 1.5 times misfire NG judgment • Catalyst damage misfire NG judgment

As shown in the following figure, pick a cylinder as the standard and name it omg 0. And the former crankshaft position speed is named omg 1, the second former crankshaft position speed is named omg 2, the third is named omg 3, etc.

(A)

(B)

#3

#2

#4

#1

#3

#2

#4

#1

#3

omg7

omg6

omg5

omg4

omg3

omg2

omg1

omg0

#2

EN-01774

(A)

Ignition order

(B)

Crankshaft position speed

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

180° Interval Difference Method Diagnostic domg 180 = (omg 1 – omg 0) – (omg 5 – omg 1)/4 value Judge as a misfire in the following cases. • domg 180 > judgment value of positive side • domg 180 ≤ judgment value of negative side (Judgment value before 180° CA)

domg180 Threshold valve (positive number)

domg180

Threshold valve (negative number)

Judged as misfire.

EN-02877

360° Interval Difference Method Diagnostic value Misfire judgment

domg 360 = (omg 1 – omg 0) – (omg 3 – omg 2) domg 360 > Judgment value → Judge as misfire

domg360 Threshold valve

domg360

Judged as misfire.

EN-03273

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

720° Interval Difference Method Diagnostic value Misfire judgment

domg 720 = (omg 1 – omg 0) – (omg 5 – omg 4) domg 720 > Judgment value → Judge as misfire

domg720

Threshold valve

domg720

Judged as misfire.

EN-03274

• FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas) • Abnormality Judgment Judgment Value (Judge that malfunction occurs when the misfire ratio is high in 1000 engine revs.) Malfunction Criteria FTP emission judgment value

Threshold Value ≥ 18 × 100/2000% in 1000 revs. (PZEV AT model) ≥ 30 × 100/2000% in 1000 revs. (AT model except for PZEV) ≥ 20 × 100/2000% in 1000 revs. (MT model)

Time Needed for Diagnosis: 1000 engine revs. Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judgment Value Malfunction Criteria FTP emission judgment value

Threshold Value < 18 × 100/2000% in 1000 revs. (PZEV AT model) < 30 × 100/2000% in 1000 revs. (AT model except for PZEV) < 20 × 100/2000% in 1000 revs. (MT model)

Time Needed for Diagnosis: 1000 engine revs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Catalyst damage misfire (Misfire occurrence level damaging catalyst) • Abnormality Judgment Judgment Value Malfunction Criteria Catalyst damage misfire judgment value

Threshold Value ≥ Value of Map 3

Map 3

Engine speed (rpm)

700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6300

0.16 (0.01) 100 100 100 80 80 67 67 57 44 44 36 20 20

0.28 (0.01) 100 100 100 80 80 67 67 57 44 44 36 20 20

0.4 (0.01) 100 100 90 80 73 62 56 44 33 38 31 20 20

Intake air (g(oz)/rev) 0.52 (0.02) 0.64 (0.02) 100 90 100 90 80 73 80 68 67 62 57 51 44 40 31 24 31 20 31 20 27 20 20 20 20 20

0.76 (0.03) 80 80 67 57 57 44 36 20 20 20 20 20 20

0.92 (0.03) 64 63 54 51 51 44 34 20 20 20 20 20 20

1.1 (0.04) 48 44 40 44 44 44 31 20 20 20 20 20 20

Time Needed for Diagnosis: 200 engine revs. Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judgment Value Malfunction Criteria Catalyst damage misfire judgment value

Threshold Value < Value of Map 3

Time Needed for Diagnosis: 200 engine revs.

AV:DTC P0302 CYLINDER 2 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

AW:DTC P0303 CYLINDER 3 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

AX:DTC P0304 CYLINDER 4 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

GD(H4SO)-87

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AY:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of knock sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(4)

(5)

(2)

(A)

(3)

EN-01707

(A)

To knock sensor harness

(1) (2)

Case Weight

(3) (4)

Piezoelectric element Nut

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-88

(5)

Resistance

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.243 V

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.243 V

Time Needed for Diagnosis: Less than 1 second

GD(H4SO)-89

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AZ:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of knock sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(4)

(5)

(2)

(A)

(3)

EN-01707

(A)

To knock sensor harness

(1) (2)

Case Weight

(3) (4)

Piezoelectric element Nut

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-90

(5)

Resistance

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.709 V

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.709 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BA:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the crankshaft position sensor. Judge as NG when the crank signal is not input even though the starter was rotated.

2. COMPONENT DESCRIPTION

(A) #1BTDC10 CA

#3BTDC10 CA

#2BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(B)

30 CA 30 CA

10 CA

EN-05538

(A)

Cam signal

(B)

Crankshaft signal

(1)

(3)

(2)

(1)

Crankshaft position sensor

EN-05539

(2)

Crank sprocket

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-92

(3)

Crankshaft half-turn

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Starter switch Crankshaft position sensor signal Battery voltage

Threshold Value ON Not detected ≥8V

Time Needed for Diagnosis: 3000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Crankshaft position sensor signal Battery voltage

Threshold Value Input exists ≥8V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BB:DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect for faults in crankshaft position sensor output properties. Judge as NG when there is a problem in the number of crankshaft signals for every revolution.

2. COMPONENT DESCRIPTION

(A) #1BTDC10 CA

#3BTDC10 CA

#2BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(B)

30 CA 30 CA

10 CA

EN-05538

(A)

Cam signal

(B)

Crankshaft signal

(1)

(3)

(2)

(1)

Crankshaft position sensor

EN-05539

(2)

Crank sprocket

3. ENABLE CONDITION Secondary Parameters Battery voltage Engine speed

Enable Conditions ≥8V < 4000 rpm

GD(H4SO)-94

(3)

Crankshaft half-turn

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously under 3000 rpm engine speed.

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Cylinder number identification Amount of crank sensor signal during 1 rev.

Threshold Value Completed Not = 30

Time Needed for Diagnosis: 10 engine revs. Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Cylinder number identification Amount of crank sensor signal during 1 rev.

Threshold Value Completed = 30

Time Needed for Diagnosis: Less than 1 second

GD(H4SO)-95

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BC:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the camshaft position sensor. Judge as NG when the number of camshaft signals remains abnormal.

2. COMPONENT DESCRIPTION

Number of camshaft signal = 2 is normal at two engine revolution.

(A) #1BTDC10 CA

#3BTDC10 CA

#2BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(B)

10 CA

30 CA 30 CA

EN-05541

(A)

Camshaft signal

(B)

Crankshaft signal

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-96

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Amount of camshaft sensor signal during 2 revs.

Threshold Value ≥8V Not = 2

Time Needed for Diagnosis: Engine two revolutions × 4 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Voltage Amount of camshaft sensor signal during 2 revs.

Threshold Value ≥8V =2

Time Needed for Diagnosis: Two engine revolutions

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BD:DTC P0341 CAMSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of camshaft position sensor output property. Judge as NG when the camshaft line signal input timing is shifted from the crankshaft signal because of timing belt tooth chip etc.

2. COMPONENT DESCRIPTION

OK

NG

OK

NG

(A) #1BTDC10 CA

#3BTDC10 CA

#2BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(B)

10 CA

30 CA 30 CA

EN-05542

(A)

Camshaft signal

(B)

(1)

Crankshaft signal

(4)

(3)

(1)

(5)

(2)

EN-01782

(1)

Boss

(3)

Air gap

(2)

Cam sprocket

(4)

Camshaft position sensor

GD(H4SO)-98

(5)

Camshaft one revolution (engine two revolutions)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Cylinder number identification Battery voltage Engine speed Engine operation Misfire Engine speed variation for 4 ms

Enable Conditions Completed ≥8V 550 rpm — 1000 rpm Idling Not detected ≤ 12799.8 rpm

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously at idle speed.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Position of camshaft position sensor signal

Threshold Value Not between BTDC 10°CA and BTDC 80°CA

Time Needed for Diagnosis: 10 engine revs. Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Position of camshaft position sensor signal

Threshold Value Between BTDC10°CA and BTDC80°CA

Time Needed for Diagnosis: Two engine revolutions

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BE:DTC P0400 EXHAUST GAS RECIRCULATION FLOW 1. OUTLINE OF DIAGNOSIS Detect EGR system malfunction. Intake manifold pressure (negative pressure) is constant because the throttle valve is fully closed during deceleration fuel cut. At this time, when the EGR valve is opened/closed, the intake manifold pressure will change. EGR System OK/NG is judged by the range of this change.

2. COMPONENT DESCRIPTION (7)

(1) (6)

(5)

(2) (4) (3)

EN-02192

(1) (2) (3)

ECM Detecting circuit Switching circuit

(4) (5)

CPU EGR valve

GD(H4SO)-100

(6) (7)

Main relay Battery power supply

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Elapsed time after starting the engine Engine coolant temperature Engine speed Intake manifold pressure (absolute pressure) Ambient air temperature Throttle position Battery voltage Atmospheric pressure Vehicle speed Fuel shut-off function Neutral switch After neutral switch ON/OFF change No load change (A/C, power steering, lighting, rear defogger, heater fan and radiator fan)

Enable Conditions ≥ 40 s ≥ 75 °C(167 °F) 1200 rpm — 2950 rpm < 44 kPa (330 mmHg, 13 inHg) ≥ 5 °C(41 °F) < 0.25 ° ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥53 km/h (32.9 MPH) In operation OFF ≥ Value from Map ≥ 5000 ms

Map Engine coolant temperature °C (°F) After neutral switch change msec

–40 (–40)

–30 (–22)

–20 (–4)

–10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

0

0

0

0

0

0

0

0

Engine coolant temperature °C (°F) After neutral switch change msec

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100 (212)

110 (230)

0

0

0

0

0

0

0

0

4. GENERAL DRIVING CYCLE During deceleration fuel cut from 53 km/h (approx. 33 MPH) or more, perform diagnosis once. Be careful of vehicle speed and engine speed. (Diagnosis will not be completed if the vehicle speed and engine speed conditions become out of specification due to deceleration.)

5. DIAGNOSTIC METHOD Measure the pressure values when the enable conditions are established, and perform diagnosis by calculating those results. 1. Label the intake manifold pressure value as PMOF1, which is observed when enable conditions are established, and set the EGR target step to 50 steps (nearly full open). 2. Name the intake manifold pressure value as PMON one second after the target EGR step is set to 50 (when the enabled conditions were established). Then set the target EGR step to 0. 3. Name the intake manifold pressure value as PMOF2 one second after the target EGR step is set to 0 (two seconds after the enabled conditions were established). • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria PMON – (PMOF1 + PMOF2)/2

Threshold Value < 2.5 kPa (18.63 mmHg, 0.7 inHg)

Time Needed for Diagnosis: 1 time Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION Start dignosis

(A)

Deceleration fuel cut

(B)

(C)

ON OFF

Diagnosis enable condition

(Open)

(D)

EGR target step (Close)

(Open) EGR actual step (Close)

PMON Intake manifold pressure (During normal condition)

PMOF2 PMOF1

DIagnostic mode timer

EN-05568

(A) (D)

3000 ms 45 step(s)

(B)

1000 ms

(C)

• Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria PMON – (PMOF1 + PMOF2)/2

Threshold Value ≥ 2.5 kPa (18.63 mmHg, 0.7 inHg)

Time Needed for Diagnosis: 1 time

GD(H4SO)-102

1000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BF:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the deterioration of the catalyst function. Though the front oxygen sensor output would change slowly with a new catalyst, the sensor output with a deteriorated catalyst becomes high and the inversion time is shortened. For this reason, the catalyst diagnosis is carried out by monitoring the front oxygen sensor output and comparing it with the front oxygen (A/F) sensor output.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(3)

(B)

(3)

(C)

(D)

EN-01713

(A)

Normal

(D)

Output waveform from the front oxygen sensor

(1)

Front oxygen (A/F) sensor

(B)

Deterioration

(C)

Output waveform from the front oxygen (A/F) sensor

(2)

Front oxygen sensor

(3)

Catalytic converter

GD(H4SO)-103

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Battery voltage Atmospheric pressure Engine coolant temperature

Estimated catalyst temperature Misfire detection every 200 rotations Learning value of evaporation gas density Sub feedback Evaporative system diagnosis Time of difference (< 0.10) between actual lambda and target lambda Vehicle speed Amount of intake air

Engine load change every 0.5 engine revs. Rear oxygen output change from 660 mV or less to 660 mV or more Elapsed time after starting the engine Purge execution calculated time

Enable Conditions ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 75 °C (167 °F) (PZEV model) ≥ 70 °C (158 °F) (except for PZEV model) ≥ 580 °C (1076 °F) (AT model) ≥ 585 °C (1085 °F) (MT model) < 5 time(s) < 0.2 In operation Not in operation ≥ 1000 ms > 75 km/h (46.6 MPH) ≥ 7 g/s (0.25 oz/s) and < 40 g/s (1.41 oz/s) < 0.02 g/rev (0 oz/rev) Experienced after fuel cut ≥ 225 s (PZEV model) ≥ 218 s (except for PZEV model) ≥0s

4. GENERAL DRIVING CYCLE Perform the diagnosis only once at a constant 75 km/h (46.6 MPH) or higher.

5. DIAGNOSTIC METHOD After the enable conditions have been established, calculate the front oxygen (A/F) sensor lambda value deviation cumulative value (Σ |(sglmdn – sglmdn–1 )|), and rear oxygen sensor output voltage deviation cumulative value (Σ |(ro2sadn – ro2sadn–1)|) in every 32 ms × 4 times. If the front oxygen (A/F) sensor lambda value deviation cumulative value (Σ |(sglmdn – sglmdn–1 )|) is the predetermined value or more, calculate the judgment value. • Abnormality Judgment If the duration of time while the following conditions are met is within the time indicated, judge as NG. Judgment Value Malfunction Criteria Σ |(ro2sadn – ro2sadn–1)| / Σ |(sglmdn – sglmdn–1)|

Threshold Value > 11 (PZEV model) > 19.5 (except for PZEV model)

Time Needed for Diagnosis: 30 — 55 seconds Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is within the predetermined time. Judgment Value Malfunction Criteria Σ |(ro2sadn – ro2sadn–1)| / Σ |(sglmdn – sglmdn–1)|

Threshold Value ≤ 11 (PZEV model) ≤ 19.5 (except for PZEV model)

Time Needed for Diagnosis: 30 — 55 seconds

GD(H4SO)-104

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BG:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK) 1. OUTLINE OF DIAGNOSIS Check if there is a leakage in fuel system or not, and perform the function diagnosis of valve.

(4) (1)

(2)

(3)

(5)

(14)

(13) (15) (8) (7) (9)

(12)

(11)

(10)

(6)

EN-07995

(1) (2) (3) (4) (5)

Fuel gauge Intake manifold Throttle body Purge control solenoid valve Engine control module (ECM)

(6) (7) (8) (9) (10)

Canister Drain valve Drain filter Shut-off valve Fuel temperature sensor

(11) (12) (13) (14) (15)

Fuel level sensor Fuel tank Fuel cut valve Fuel tank pressure sensor Vent valve

In this system diagnosis, check for leakage and valve function is conducted by changing the fuel tank pressure and monitoring the pressure change using the fuel tank pressure sensor. When in 0.04 inch diagnosis, perform in the order of mode Z → mode A → mode B → mode C and mode D; When in 0.02 inch diagnosis, perform in the order of mode A → mode B → mode C → mode D and mode E.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

0.04-inch Diagnosis

Mode Z

OK

Mode A

OK

Mode B

OK

Mode C

OK

Mode D

OK

NG Early OK Large leakage judgement

END

Cancel

NG

Mode Z Extend

NG OK

EN-02872

Mode Mode Z (Purge control solenoid valve opening failure diagnosis) Mode A (Estimated evaporation amount) Mode B (Sealed negative pressure, large leakage judgment) Mode C (Pressure increase check, advanced OK judgment)

Mode Description

Diagnosis Period

Perform purge control solenoid valve opening failure diagnosis from the size of tank pressure variation from diagnosis start.

5000 ms + 3000 ms — 5000 ms + 3000 ms + 13000 ms

Calculate the tank pressure change amount (P1).

10000 ms

Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank. If the tank pressure cannot be reduced, it is diagnosed as large leak.

0 — 10000 ms + 25000 ms

Wait until the tank pressure returns to the target (start level of P2 calculation). If the tank pressure does not become the value, make advanced OK judgment.

0 — 14013 ms

Mode D Calculate the tank pressure variation (P2), and obtain the diagnostic (Negative pressure variation value using P1 found in Mode A. measurement, evaporation leakPerform the evaporation diagnosis using the diagnostic value. age diagnosis)

0 ms + 10000 ms

Mode Table for Evaporative Emission Control System Diagnosis Mode Mode Z Mode A Mode B Mode C Mode D

Behavior of tank internal pressure under normal conditions Diagnostic item Roughly the same as barometric pressure (Same as 0 kPa Purge control solenoid valve is judged (0 mmHg, 0 inHg)) to be open. Pressure is in proportion to amount of evaporative emission. Negative pressure is formed due to intake manifold negative pressure Reaches target pressure Pressure change is small.

— Large leak

P0457 None P0457

— EVAP system large leak determination. [1.0 mm (0.04 in)]

GD(H4SO)-106

DTC

None P0442

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

0.02-inch Diagnosis

Mode A

OK

Mode B

OK

Mode C

OK

OK

Mode D

Mode E

Cancel Early OK 2 Cancel

END

Early OK 1 Cancel Cancel Cancel

EN-02871

Mode Mode A (0 point compensation)

Mode Description When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg).

Diagnosis Period 0 — Value of Map 1

Mode B (Negative pressure introduced)

Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank.

Mode C (Negative pressure maintained) Mode D (Negative pressure change calculated)

Wait until the tank pressure returns to the target (start level of P2 calculation).

Value from Map 3

Calculate the time it takes for the tank pressure to change to the Mode E shifting pressure. If the tank pressure does not change to the Mode E shifting pressure, make advanced OK judgment.

0 — 0 ms + Value from Map 4

Mode E (Evaporation generated amount calculation)

Calculate the amount of evaporation (P1).

GD(H4SO)-107

0 — Value of Map 2

0 — 0 ms + Value from Map 4 + Value from Map 5

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Map 1 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

20, 5.28, 4.4 6530

30, 7.93, 6.6 6660

10.5

27, 7.13, 5.94

43, 11.36, 9.46

20280

20621

21816

10.5

27, 7.13, 5.94

43, 11.36, 9.46

21208

19288

9742

59.5, 15.72, 13.09 8057

20, 5.28, 4.4 200000

30, 7.93, 6.6 200000

20, 5.28, 4.4 70000

30, 7.93, 6.6 60000

10 6400

40, 10.57, 8.8 7020

50, 13.21, 11 7380

60, 15.85, 13.2 7380

40, 10.57, 8.8 200000

50, 13.21, 11 200000

60, 15.85, 13.2 200000

40, 10.57, 8.8 60000

50, 13.21, 11 60000

60, 15.85, 13.2 60000

Map 2 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

59.5, 15.72, 13.09 21816

Map 3 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

Map4 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

10 200000

Map 5 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

10 80000

2. COMPONENT DESCRIPTION Drain valve controls the ambient air to be introduced to the canister.

EN-02293

GD(H4SO)-108

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION 0.04-inch Diagnosis Secondary Parameters Battery voltage Atmospheric pressure Total time of canister purge operation Learning value of evaporation gas density Engine speed Fuel tank pressure Intake manifold relative vacuum (relative pressure) Continuous time of the status where fuel level is 10.5 2 (2.77 US gal, 2.31 Imp gal) — 59.5 2 (15.72 US gal, 13.09 Imp gal) Closed air/fuel ratio control Fuel temperature Intake air temperature Pressure variation every one second Minimum pressure variation value every one second – Maximum pressure variation value every one second Fuel level variation every 128 ms Air fuel ratio Elapsed time after starting the engine or Elapsed time after starting the engine

or Elapsed time after starting the engine

or Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 120000 ms < 0.08 1050 rpm — 4000 rpm ≥ –4 kPa (–30 mmHg, –1.2 inHg) ≥ –13.3 kPa (–100 mmHg, –3.9 inHg) ≥ 37000 ms

In operation –10 °C (14 °F) — 45 °C (113 °F) ≥ –10 °C (14 °F) < 1.7 mmHg (Mode A) < 1.7 mmHg (Mode D) < 1.7 mmHg (Mode A) < 1.7 mmHg (Mode D) < Value of Map 6 0.76 — 1.25 ≥ 855 s ≥ 335 s and Vehicle speed 65 km/h (40.4 MPH) or more ≥ 335 s and Continue for 40000 ms or more at a vehicle speed of 50 km/h (31.1 MPH) or more ≥ 335 s and Continue for 83000 ms or more at a vehicle speed of 24 km/h (14.9 MPH) or more

Map 6 Fuel level (2, US gal, Imp gal)

10, 2.64, 2.2

20, 5.28, 4.4

25, 6.61, 5.5

30, 7.93, 6.6

43, 11.36, 9.46

45, 11.89, 9.9

50, 13.21, 11

60, 15.85, 13.2

Change (2, US gal, Imp gal)

4, 1.06, 0.88

5, 1.32, 1.1

6.5, 1.72, 1.43

4, 1.06, 0.88

5, 1.32, 1.1

5, 1.32, 1.1

6, 1.59, 1.32

8, 2.11, 1.76

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

0.02-inch Diagnosis Secondary Parameters At starting a diagnosis Evap. diagnosis Battery voltage Atmospheric pressure Time since last incomplete 0.02-inch leakage diagnosis When cancelling in mode A When cancelling in other than mode A Total time of canister purge operation Elapsed time after starting the engine Fuel temperature Continuous time of the status where fuel level is 10.5 2 (2.77 US gal, 2.31 Imp gal) — 59.5 2 (15.72 US gal, 13.09 Imp gal) Intake manifold relative vacuum (relative pressure) Fuel tank pressure Closed air/fuel ratio control Engine speed Vehicle speed

During diagnosis Change of fuel level Pressure variation every one second Minimum pressure variation value every one second – Maximum pressure variation value every one second | Tank pressure variation every one second | Barometric pressure change

Enable Conditions Incomplete ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg)

> 120000 ms > 230000 ms ≥ 120000 ms ≥ 120 s –10 °C (14 °F) — 55 °C (131 °F) ≥ 37000 ms

≥ –8 kPa (–60 mmHg, –2.4 inHg) –0.7 kPa (–5 mmHg, –0.2 inHg) — 0.4 kPa (2.9 mmHg, 0.1 inHg) In operation 1050 rpm — 4000 rpm Continue the status of 50 km/h (31.1 MPH) — 510 km/h (316.9 MPH) for 125000 ms or more. or ≥ 100 km/h (62.1 MPH) or Continue for 40000 ms or more at a vehicle speed of 90 km/h (55.9 MPH) or more or Continue for 90000 ms or more at a vehicle speed of 80 km/h (49.7 MPH) or more ≤ Value of Map 7 < 0.1 kPa (0.44 mmHg, 0 inHg) < 0.1 kPa (0.51 mmHg, 0 inHg) (Mode D)

≤ 0.1 kPa (0.75 mmHg, 0 inHg) –0.5 kPa (–3.6 mmHg, –0.1 inHg) — 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode D) –0.3 kPa (–2.4 mmHg, –0.1 inHg) — 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode E)

Map 7 Fuel level (2, US gal, Imp gal)

10, 2.64, 2.2

20, 5.28, 4.4

25, 6.61, 5.5

30, 7.93, 6.6

43, 11.36, 9.46

45, 11.89, 9.9

50, 13.21, 11

60, 15.85, 13.2

Change (2, US gal, Imp gal)

4, 1.06, 0.88

5, 1.32, 1.1

6.5, 1.72, 1.43

4, 1.06, 0.88

5, 1.32, 1.1

5, 1.32, 1.1

6, 1.59, 1.32

8, 2.11, 1.76

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. GENERAL DRIVING CYCLE 0.04-inch Diagnosis • Perform the diagnosis only once in 335 seconds or more after starting the engine, at a constant speed of 24 km/h (15 MPH) or more for 83 seconds or more. • Pay attention to the fuel temperature and fuel level. 0.02-inch Diagnosis • Perform the diagnosis after 125 seconds or more have elapsed at a constant engine speed of 50 km/h (31 MPH) or higher to judge as NG or OK. • If judgment cannot be made, repeat the diagnosis. • Pay attention to the fuel level.

5. DIAGNOSTIC METHOD Purge control solenoid valve stuck open fault diagnosis DTC P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) Purpose of Mode Z When performing the leakage diagnosis of EVAP system, the purge control solenoid valve must operate normally. Therefore, mode Z is used to diagnose the purge control solenoid valve stuck open condition. Note that if a purge control solenoid valve stuck open fault is detected, the EVAP system leakage diagnosis is cancelled. Diagnostic method Purge control solenoid valve functional diagnosis is performed by monitoring the tank pressure in mode Z. • Abnormality Judgment If OK judgment cannot be made, extend Mode Z, and Judge as NG when the following conditions are established after predetermined amount of time. Judgment Value Malfunction Criteria evptez – evptezha evptezini Time of no fuel sloshing with value from Map 6 or more

Threshold Value > 0.9 kPa (6.5 mmHg, 0.3 inHg) ≤ 0.4 kPa (2.9 mmHg, 0.1 inHg) ≥ 40000 ms

DTC P0457

Time Needed for Diagnosis: 5000 ms + 3000 ms + 13000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. When judgment for purge control solenoid valve stuck open NG is made, end the evaporative diagnosis. Cancel the evaporative diagnosis when the OK/NG judgment for purge control solenoid valve stuck open cannot be made in Mode Z. • Normality Judgment Judge as OK and change to Mode A when the following conditions are established after 3000 ms has passed since Mode Z started. Judgment Value Malfunction Criteria evptez – evptezha

Threshold Value ≤ 0.4 kPa (3 mmHg, 0.1 inHg)

DTC P0457

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Normal

(1)

(2) evptez evptezha

evptezini

(3) 0

(4)

(5) EN-02869

(1) (2)

Mode Z 3000 ms

(3) (4)

Fuel tank pressure 0.4 kPa (3 mmHg, 0.1 inHg)

(5)

OK judgment

evptez – evptezha ≤ 0.4 kPa (3 mmHg, 0.1 inHg) Normal when above is established Time Needed for Diagnosis: 5000 ms + 3000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Purge control solenoid valve Open Fixation

(1)

(2) (3)

(6) evptez evptezini

(4) 0

(5)

evptezha

(7)

(8)

EN-02870

(1) (2) (3)

Mode Z Extended mode Z 5000 ms + 3000 ms + 13000 ms

(4) (5) (6)

Fuel tank pressure 0.9 kPa (6.5 mmHg, 0.3 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg)

• evptezini ≤ 0.4 kPa (2.9 mmHg, 0.1 inHg) • evptez – evptezha > 0.9 kPa (6.5 mmHg, 0.3 inHg) • No fuel sloshing with value from Map 6 or more lasts for 40000 ms. Judge as abnormal when all are established.

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(7) (8)

40000 ms no fuel sloshing NG judgment

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Leak Diagnosis DTC P0442 Evaporative Emission Control System Leak Detected (Small Leak) P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) • The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. • The diagnosis is divided into the following five phases. Mode A: (Estimated evaporation gas amount) Calculate the tank pressure change amount (P1) when using mode A. After calculating P1, switch to mode B. Mode B: (Negative pressure sealed) Introduce negative pressure in the intake manifold to the tank. Approx. 0 → –1.4 kPa (0 → –10.5 mmHg, 0 → –0.4 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. In this case, if the tank pressure does not reach the target negative pressure, judge that there is a large leakage in the system and terminate the evaporative emission control system diagnosis. Abnormality Judgment Judge as NG (large leakage) when the following conditions are established. Judgment Value Malfunction Criteria Time to reach target negative pressure or Mode B time (Min. pressure value in tank when in mode B) – (Tank pressure when mode B started)

Threshold Value DTC ≥ 10000 ms + 25000 ms P0457 ≥ 10000 ms > –0.5 kPa (–4 mmHg, –0.2 inHg)

Time Needed for Diagnosis: 5000 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms Mode C: (Check pressure rise) Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.) Change to Mode D when the tank pressure returns to the start level of P2 calculation. Judge immediate OK and change to Mode E when it does not return in spite of spending the specified time. Tank pressure when starting calculation of P2 –1.3 kPa (–9.75 mmHg, –0.4 inHg)

Time for advanced OK judgment 14013 ms

Time Needed for Diagnosis: 5000 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 14013 ms Mode D: (Measure amount of negative pressure change) Monitor the tank pressure change amount when using mode D. In this case, the tank pressure increases, (nears barometric pressure) because evaporation occurs. However, if any leakage exists, the pressure increases additionally in proportion to this leakage. The pressure variation of this tank is P2. After calculating P2, perform a small leak diagnosis according to the items below. When Mode D is ended Assign tank variations measured in Mode A and Mode D, P1 and P2, to the formula below, judge small leaks in the system. If the measured judgment value exceeds the threshold value, it is judged to be a malfunction.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Abnormality Judgment Judge as NG when the following conditions are established within the predetermined time. Judge as OK and clear the NG if the following conditions are not established within the predetermined time. Judgment Value Malfunction Criteria P2 – 1.5 – × P1 P2: Tank pressure that changes every 10000 ms in mode D P1: Tank pressure that changes every 10000 ms in mode A

Threshold Value > Value of Map 8

DTC P0442

*1.5 –: Evaporation amount compensation value when below negative pressure (Amount of evaporation occurrence increases as a vacuum condition increases.)

Map 8 Fault criteria limit for Evaporative emission control system diagnosis Fuel temperature vs. Fuel level 10.5 2 (2.77 US gal, 2.31 Imp gal) 27 2 (7.13 US gal, 5.94 Imp gal) 43 2 (11.36 US gal, 9.46 Imp gal) 59.5 2 (15.72 US gal, 13.09 Imp gal)

15 °C (59 °F)

25 °C (77 °F)

35 °C (95 °F)

45 °C (113 °F)

0.3 kPa (2.1 mmHg, 0.1 inHg) 0.3 kPa (2.32 mmHg, 0.1 inHg)

0.3 kPa (2.1 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg)

0.3 kPa (2.3 mmHg, 0.1 inHg) 0.4 kPa (2.73 mmHg, 0.1 inHg)

0.3 kPa (2.4 mmHg, 0.1 inHg) 0.4 kPa (2.88 mmHg, 0.1 inHg)

0.4 kPa (2.88 mmHg, 0.1 inHg)

0.4 kPa (2.97 mmHg, 0.1 inHg)

0.4 kPa (3.23 mmHg, 0.1 inHg)

0.5 kPa (3.43 mmHg, 0.1 inHg)

0.5 kPa (3.5 mmHg, 0.1 inHg)

0.5 kPa (3.5 mmHg, 0.1 inHg)

0.5 kPa (3.5 mmHg, 0.1 inHg)

0.5 kPa (3.7 mmHg, 0.1 inHg)

Time Needed for Diagnosis: 5000 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 14013 ms + 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Leak Diagnosis DTC P0456 Evaporative Emission Control System Leak Detected (very small leak) • The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. • The diagnosis is divided into the following five phases. Mode A: (0 point compensation) When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg). Shift to mode B when returned to the 0 point. Cancel the diagnosis when 0 point does not return in the specified time. Mode B: (Negative pressure introduced) Introduce negative pressure in the intake manifold to the tank. Approx. 0 → –2 kPa (0 → –15 mmHg, 0 → –0.6 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. When the tank internal pressure does not reach the target vacuum pressure, the diagnosis is cancelled. Mode C: (Negative pressure maintained) Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.) Change to Mode D either when the tank pressure returns to the start level of P2 calculation, or when the predetermined amount of time has passed. Mode D: (Calculate the amount of negative pressure change) Monitor the tank pressure in mode D, calculate (P2) the pressure change in the tank, and measure the time (evpdset) for the tank pressure to change to the Mode E shifting pressure. When the Mode E shifting pressure is reached, Mode E is entered. If it does not change to the Mode E shifting pressure after the predetermined amount of time has passed, make advanced OK judgment or cancel the diagnosis.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Normality Judgment Judge as OK when the following conditions are established. Judgment Value Malfunction Criteria Advanced OK judgment 1 Mode D time Tank internal pressure Advanced OK judgment 2 Mode D time P2

Threshold Value ≥ 0 ms + 20000 ms ≤ Value of Map 9 ≥ 0 ms + Value of Map 10 ≤ Value of Map 11

Map 9 10.5, 2.77, 2.31 –1.9, –14.61, Tank pressure (kPa, mmHg, inHgl) –0.6

27, 7.13, 5.94 –1.9, –14.61, –0.6

43, 11.36, 9.46 –1.8, –13.64, –0.5

59.5, 15.72, 13.09 –1.8, –13.13, –0.5

10, 2.64, 2.2

20, 5.28, 4.4

30, 7.93, 6.6

40, 10.57, 8.8

50, 13.21, 11

200000

200000

200000

200000

200000

27, 7.13, 5.94 1.1, 8.52, 0.3

43, 11.36, 9.46 1.3, 10, 0.4

59.5, 15.72, 13.09 1.3, 10, 0.4

Fuel level (2, US gal, Imp gal)

Map 10 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

60, 15.85, 13.2 200000

Map 11 10.5, 2.77, 2.31 Tank pressure (kPa, mmHg, inHgl) 1.1, 8.52, 0.3

Fuel level (2, US gal, Imp gal)

Mode E: (Evaporation occurrence amount calculation) Calculate the change of tank pressure with the time evpdset (P1) to judge as NG/OK according to the value of P1. (ambiguous determination acceptable).

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria P1

Threshold Value < Value of Map 12

Map 12 Malfunction criteria limit for evaporation diagnosis Time (evpdset) vs Fuel level 10.5 2 (2.77 US gal, 2.31 Imp gal) 27 2 (7.13 US gal, 5.94 Imp gal) 43 2 (11.36 US gal, 9.46 Imp gal) 59.5 2 (15.72 US gal, 13.09 Imp gal)

40000 ms

60000 ms

105000 ms

110000 ms

140000 ms

160000 ms

180000 ms

200000 ms

0 kPa 0.1 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.4 kPa 0.4 kPa 0.4 kPa (0.00 mmHg, (0.70 mmHg, (2.18 mmHg, (2.23 mmHg, (2.53 mmHg, (2.72 mmHg, (2.90 mmHg, (2.90 mmHg, 0 inHg) 0 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.4 kPa 0.4 kPa 0.4 kPa 0.4 kPa 0 kPa 0.2 kPa 0.3 kPa 0.3 kPa (0.00 mmHg, (1.81 mmHg, (2.46 mmHg, (2.53 mmHg, (2.90 mmHg, (2.90 mmHg, (2.90 mmHg, (2.90 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0 inHg) 0 kPa 0.2 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0 kPa (0.00 mmHg, (1.53 mmHg, (2.49 mmHg, (2.60 mmHg, (2.60 mmHg, (2.60 mmHg, (2.60 mmHg, (0.00 mmHg, 0 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0 inHg) 0.3 kPa 0.3 kPa 0.3 kPa 0.2 kPa 0 kPa 0 kPa 0.2 kPa 0.3 kPa (0.00 mmHg, (1.31 mmHg, (2.53 mmHg, (2.53 mmHg, (2.53 mmHg, (2.53 mmHg, (1.26 mmHg, (0.00 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0 inHg) 0 inHg) 0 inHg) 0.1 inHg) 0.1 inHg)

Time needed for diagnosis: Value from Map 1 + Value from Map 2 + Value from Map 3 + 0 ms + Value from Map 4 + 0 ms + Value from Map 4 + Value from Map 5 Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK when the following conditions are established. Judgment Value Malfunction Criteria P1

Threshold Value > Value of Map 13

Map 13 Malfunction criteria limit for evaporation diagnosis Time (evpdset) vs Fuel level 10.5 2 (2.77 US gal, 2.31 Imp gal) 27 2 (7.13 US gal, 5.94 Imp gal) 43 2 (11.36 US gal, 9.46 Imp gal) 59.5 2 (15.72 US gal, 13.09 Imp gal)

20000 ms

60000 ms

105000 ms

110000 ms

140000 ms

160000 ms

180000 ms

200000 ms

0 kPa 0.3 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.6 kPa 0.6 kPa 0.6 kPa (0.00 mmHg, (2.20 mmHg, (3.68 mmHg, (3.73 mmHg, (4.03 mmHg, (4.22 mmHg, (4.40 mmHg, (4.40 mmHg, 0 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0 kPa 0.4 kPa 0.5 kPa 0.5 kPa 0.6 kPa 0.6 kPa 0.6 kPa 0.6 kPa (0.00 mmHg, (3.31 mmHg, (3.96 mmHg, (4.03 mmHg, (4.40 mmHg, (4.40 mmHg, (4.40 mmHg, (4.40 mmHg, 0 inHg) 0.1 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0 kPa 0.4 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.2 kPa (0.00 mmHg, (3.03 mmHg, (3.99 mmHg, (4.10 mmHg, (4.10 mmHg, (4.10 mmHg, (4.10 mmHg, (1.50 mmHg, 0 inHg) 0.1 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.1 inHg) 0.5 kPa 0.5 kPa 0.5 kPa 0.4 kPa 0.2 kPa 0 kPa 0.4 kPa 0.5 kPa (0.00 mmHg, (2.81 mmHg, (4.03 mmHg, (4.03 mmHg, (4.03 mmHg, (4.03 mmHg, (2.76 mmHg, (1.50 mmHg, 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.1 inHg) 0.1 inHg) 0 inHg) 0.1 inHg) 0.2 inHg)

Time needed for diagnosis: Value from Map 1 + Value from Map 2 + Value from Map 3 + 0 ms + Value from Map 4 + 0 ms + Value from Map 4 + Value from Map 5

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BH:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the drain valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (19)

(14)

(9)

(10)

(15)

(11)

(16)

(12)

(8)

(13)

(7)

(17)

(4)

(2)

(5)

(19)

(6)

(1)

(18)

(3) EN-02294

(1) (2) (3) (4) (5) (6) (7)

Bobbin Coil Diode Stator core End plate Body Yoke

(8) (9) (10) (11) (12) (13) (14)

Magnetic plate Shaft Plate Valve Housing Filter Retainer

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(15) (16) (17) (18) (19)

Diaphragm Movable core Spring Cover O-ring

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal

Threshold Value ≥ 10.9 V ≥ 1 second Low

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal

Threshold Value ≥ 10.9 V ≥ 1 second High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BI: DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the drain valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (19)

(14)

(9)

(10)

(15)

(11)

(16)

(12)

(8)

(13)

(7)

(17)

(4)

(2)

(5)

(19)

(6)

(1)

(18)

(3) EN-02294

(1) (2) (3) (4) (5) (6) (7)

Bobbin Coil Diode Stator core End plate Body Yoke

(8) (9) (10) (11) (12) (13) (14)

Magnetic plate Shaft Plate Valve Housing Filter Retainer

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(15) (16) (17) (18) (19)

Diaphragm Movable core Spring Cover O-ring

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal

Threshold Value ≥ 10.9 V ≥ 1 second High

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal

Threshold Value ≥ 10.9 V ≥ 1 second Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BJ:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR 1. OUTLINE OF DIAGNOSIS Detect the tank pressure sensor output property abnormality. Judge as NG when there is no pressure variation, which should exist in the tank, considering the engine status.

2. COMPONENT DESCRIPTION

(A) (1)

(2)

(B) (C)

EN-04462

(A)

Output voltage

(B)

Input voltage

(1)

Connector

(2)

Terminals

(C)

To fuel tank

3. ENABLE CONDITION Secondary Parameters Elapsed time after starting the engine Fuel level Fuel temperature Battery voltage Barometric pressure

Enable Conditions ≥ 60 s ≥ 9.6 2 (2.54 US gal, 2.11 Imp gal) < 35 °C (95 °F) ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg)

4. GENERAL DRIVING CYCLE • Perform the diagnosis continuously after 60 s have passed since the engine started. • Pay attention to the fuel level and temperature.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Number of times that the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is 2 2 (0.53 US gal, 0.44 Imp gal) or more (with enable condition established) Maximum – Minimum tank pressure (with enable condition completed) Maximum – Minimum fuel temperature (with enable condition completed)

Threshold Value ≥ 16 time(s)

< 0 kPa (0.375 mmHg, 0 inHg) ≥ 7 °C (44.6 °F)

If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is less than 2 2 (0.53 US gal, 0.44 Imp gal), extend 60 s and make judgment with the Max. and Min. values for the fuel level in 60 s × 2. 60 s If a difference does not appear, extend the time (60 s × 3, 60 s × 4, 60 s × 5) and continue the judgment. If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is 2 2 (0.53 US gal, 0.44 Imp gal) or more, the diagnosis counter counts up. Time Needed for Diagnosis: 60 s × 16 time(s) or more Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Maximum — Minimum tank pressure

Threshold Value ≥ 0 kPa (0.375 mmHg, 0 inHg)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BK:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the fuel tank pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A) (1)

(2)

(B) (C)

EN-04462

(A)

Output voltage

(B)

Input voltage

(1)

Connector

(2)

Terminals

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(C)

To fuel tank

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Fuel tank pressure Battery voltage

Threshold Value < –7.4 kPa (–55.6 mmHg, –2.2 inHg) ≥ 10.9 V

Time Needed for Diagnosis: 15000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Fuel tank pressure Battery voltage

Threshold Value ≥ –7.4 kPa (–55.6 mmHg, –2.2 inHg) ≥ 10.9 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BL:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the fuel tank pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A) (1)

(2)

(B) (C)

EN-04462

(A)

Output voltage

(B)

Input voltage

(1)

Connector

(2)

Terminals

(C)

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Vehicle speed All conditions of EVAP canister purge Learning value of evaporation gas concentration (left and right) Main feedback compensation coefficient (left and right) Battery voltage

Enable Conditions ≥ 5000 ms ≥ 2 km/h (1.2 MPH) Completed < 0.08 ≥ 0.9 ≥ 10.9 V

4. GENERAL DRIVING CYCLE Perform the diagnosis when purging enable conditions are met without idling.

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To fuel tank

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Fuel tank pressure Fuel temperature Atmospheric pressure

Threshold Value ≥ 7.9 kPa (59.6 mmHg, 2.3 inHg) < 35 °C (95 °F) ≥ 75 kPa (563 mmHg, 22.2 inHg)

Time Needed for Diagnosis: 15000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Fuel tank pressure

Threshold Value < 7.9 kPa (59.6 mmHg, 2.3 inHg)

Time Needed for Diagnosis: Less than 1 second

BM:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0442.

BN:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0442.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BO:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the purge control solenoid valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (B)

(A)

EN-02197

(A)

To canister

(B)

To intake manifold

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 1 second

4. GENERAL DRIVING CYCLE Always perform the diagnosis after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Duty ratio of “ON” Terminal output voltage

Threshold Value < 0.75 Low

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal output voltage

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BP:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the purge control solenoid valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (B)

(A)

EN-02197

(A)

To canister

(B)

To intake manifold

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 1 second

4. GENERAL DRIVING CYCLE Always perform the diagnosis after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Duty ratio of “ON” Terminal output voltage

Threshold Value ≥ 0.25 High

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal output voltage

Threshold Value Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BQ:DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect malfunctions of the fuel level sensor output property. If the fuel level does not vary in a particular driving condition / engine condition where it should, judge as NG.

2. COMPONENT DESCRIPTION

(A)

0

(B)

EN-01734

(A)

Fuel level

(B)

Resistance

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Accumulated amount of intake air Max. – min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine

Threshold Value ≥ 330957 g (11672.85 oz) < 2.6 2 (0.69 US gal, 0.57 Imp gal) ≥ 10.9 V < 4000 rpm ≥ 5000 ms

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Accumulated amount of intake air Max. – min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine

Threshold Value ≥ 330957 g (11672.85 oz) ≥ 2.6 2 (0.69 US gal, 0.57 Imp gal) ≥ 10.9 V < 4000 rpm ≥ 5000 ms

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BR:DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel level sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(5)

(1)

(4)

(2)

(3)

EN-05371

(1) (2)

Engine control module (ECM) Fuel level sensor

(3) (5)

Fuel sub level sensor Body integrated unit

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Detecting circuit

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms < 0.173 V

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms ≥ 0.173 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BS:DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel level sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(5)

(1)

(4)

(2)

(3)

EN-05371

(1) (2)

Engine control module (ECM) Fuel level sensor

(3) (5)

Fuel sub level sensor Body integrated unit

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Detecting circuit

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms ≥ 7.212 V

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms < 7.212 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BT:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT 1. OUTLINE OF DIAGNOSIS Detect the unstable output faults from the fuel level sensor caused by noise. Judge as NG when the max. value and cumulative value of output voltage variation of the fuel level sensor is larger than the threshold value.

2. ENABLE CONDITION Malfunction Criteria Engine speed Elapsed time after starting the engine Battery voltage Idle switch Fuel level

Vehicle speed = 0 km/h (0 MPH)

Threshold Value ≥ 500 rpm ≥ 1 second ≥ 10.9 V ON ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) and < 59.5 2 (15.72 US gal, 13.09 Imp gal) ≥ 10000 ms

3. GENERAL DRIVING CYCLE • Always perform the diagnosis continuously at idle speed. • Pay attention to the fuel level.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. DIAGNOSTIC METHOD Calculate the Max. value (DELFLMAX) and cumulative value (SUMFL) of output voltage variation of fuel level sensor during 12.2 seconds. Judge it normal when both max. and cumulative values are not over the threshold value. Otherwise, when either of them is over the threshold value, the diagnosis counter counts up. Judge as NG if the counter indicated 4 time(s).

Diagnosis condition

(A) Diagnosis timer

Fuel level sensor A/D value

(C) (D)

Amount of Fuel level output voltage variation

Calculate the Max. value (DELFLMAX) and the cumulative value (SUMFL).

5

6

4 3 2 1 Diagnosis counter

0

(B) EN-05569

(A) (D)

12288 ms Normal

(B)

NG at 4 time(s) counts

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(C)

Malfunction

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Integrated times of the condition reaching follows, DELFLMAX or SUMFL At this time, DELFLMAX: Maximum difference of sensor output for 12288 ms SUMFL: Integrated value of the sensor output deviation for12288 ms

Threshold Value ≥ 4 time(s) ≥ Value from Map ≥ 23.8 V

Map Fuel level (2, US gal, Imp gal) Measured voltage (V)

10, 2.64, 2.2 0.248

20, 5.28, 4.4 0.519

25, 6.61, 5.5 0.796

30, 7.93, 6.6 0.6

43, 11.36, 9.46 1.025

45, 11.89, 9.9 1.069

50, 13.21, 11 1.402

The diagnosis counter does not count up when the following conditions are completed within 12288 ms. Maximum value – minimum value of change of tank pressure during 12288 ms Maximum value – minimum value of battery voltage during 12288 ms

≥ 0 kPa (0.375 mmHg, 0 inHg) ≥ 1.09 V

Time Needed for Diagnosis: 12288 ms × 4 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Threshold Value DELFLMAX < Value from Map SUMFL < 23.8 V At this time, DELFLMAX: Maximum difference of sensor output for 12288 ms SUMFL: Integrated value of the sensor output deviation for12288 ms

Time Needed for Diagnosis: 12288 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BU:DTC P0500 VEHICLE SPEED SENSOR “A” 1. OUTLINE OF DIAGNOSIS Judge as NG when outside of the judgment value. Judge NG when the received data from VDCCM&H/U is abnormal vehicle speed, and the vehicle speed data is impossible.

2. COMPONENT DESCRIPTION Vehicle speed signals are taken in to the VDC control module and hydraulic control unit, and normal/erroneous data of the ABS wheel speed sensor is received by CAN communication from the VDC control module and hydraulic control unit.

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 2000 ms

4. GENERAL DRIVING CYCLE Always perform diagnosis more than 2000 ms after starting the engine.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Front ABS wheel speed sensor status Either of the following is established Front left wheel speed Front right wheel speed

Threshold Value Malfunction ≥ 300 km/h (186.4 MPH) ≥ 300 km/h (186.4 MPH)

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Front left wheel speed

Front right wheel speed

Threshold Value > 0 km/h (0 MPH) and < 300 km/h (186.4 MPH) > 0 km/h (0 MPH) and < 300 km/h (186.4 MPH)

Time Needed for Diagnosis: 2500 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BV:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED 1. OUTLINE OF DIAGNOSIS Detect the malfunction that actual engine speed is not close to target engine speed during idling. Judge as NG when actual engine speed is not close to target engine speed during idling.

2. ENABLE CONDITION Secondary Parameters Engine coolant temperature Battery voltage Atmospheric pressure Fuel level Elapsed time after starting the engine Feedback of ISC Lambda value (left and right)

After switching air conditioner to ON/ OFF After intake manifold pressure changes by 4 kPa (30 mmHg, 1.2 inHg) or more. Elapsed time after switching neutral position switch to ON/OFF Vehicle speed

Enable Conditions ≥ 75 °C (167 °F) ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 9.6 2 (2.54 US gal, 2.11 Imp gal) ≥ 10.49 s In operation ≥ 0.81 and < 1.1 ≥ 5.1 s > 5.1 s > 5.1 s 0 km/h (0 MPH)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling after warming up engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Actual engine speed — Targeted engine speed Feedback compensation for ISC

Threshold Value < –100 rpm Max.

Time Needed for Diagnosis: 10 s × 3 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Actual engine speed — Targeted engine speed

Threshold Value ≥ –100 rpm

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BW:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED 1. OUTLINE OF DIAGNOSIS Detect the malfunction that actual engine speed is not close to target engine speed during idling. Judge as NG when actual engine speed is not close to target engine speed during idling.

2. ENABLE CONDITION Secondary Parameters Engine coolant temperature Battery voltage Atmospheric pressure Fuel level Elapsed time after starting the engine Feedback of ISC Lambda value (left and right)

After switching air conditioner to ON/ OFF After intake manifold pressure changes by 4 kPa (30 mmHg, 1.2 inHg) or more. Elapsed time after switching neutral position switch to ON/OFF Vehicle speed

Enable Conditions ≥ 75 °C (167 °F) ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 9.6 2 (2.54 US gal, 2.11 Imp gal) ≥ 10.49 s In operation ≥ 0.81 and < 1.1 ≥ 5.1 s > 5.1 s > 5.1 s 0 km/h (0 MPH)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling after warming up engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Actual – Target engine speed Feedback value for ISC

Threshold Value ≥ 200 rpm Min.

Time Needed for Diagnosis: 10 s × 3 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Actual – Target engine speed

Threshold Value < 200 rpm

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BX:DTC P0512 STARTER REQUEST CIRCUIT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of starter SW. Judge as ON NG when the starter SW signal remains ON.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Engine condition Starter OFF signal Battery voltage

Threshold Value After engine starting Not detected ≥8V

Time Needed for Diagnosis: 180000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Starter OFF signal Battery voltage

Threshold Value Detected ≥8V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BY:DTC P0513 INCORRECT IMMOBILIZER KEY 1. OUTLINE OF DIAGNOSIS DTC

Item

P0513

Incorrect Immobilizer Key

P1570 P1571

Antenna Reference Code Incompatibility

P1572

IMM Circuit Failure (Except Antenna Circuit)

P1574

Key Communication Failure

P1576 P1577

EGI Control Module EEPROM IMM Control Module EEPROM

P1578

Meter Failure

Outline of Diagnosis Incorrect immobilizer key (Use of unregistered key in body integrated unit) Faulty antenna Reference code incompatibility between body integrated unit and ECM Communication failure between body integrated unit and ECM Failure of body integrated unit to verify key (transponder) ID code or transponder failure ECM malfunctioning Body integrated unit malfunctioning Reference code incompatibility between body integrated unit and combination meter

2. ENABLE CONDITION When starting the engine.

3. GENERAL DRIVING CYCLE Perform the diagnosis only after starting the engine.

4. DIAGNOSTIC METHOD Judge as NG when the conditions for the outline of the diagnosis of the top are established.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BZ:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR 1. OUTLINE OF DIAGNOSIS Detect the malfunction of microcomputer (RAM). When there is a problem in the main CPU normal RAM, or the sub CPU normal RAM, judge as NG. Judge as OK when both are operating properly. If it is possible to write data to the whole area of RAM in the initial routine, and is possible to read the same data, it is judged as OK, and if not, NG.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

Diagnosis with the initial routine.

3. GENERAL DRIVING CYCLE Perform the diagnosis as soon as the ignition switch is turned to ON.

4. DIAGNOSTIC METHOD Abnormality Judgment Judge as NG if the criteria below are met. Judgment Value Malfunction Criteria Main CPU normal RAM abnormal Write 5AA5A55A and then read. (Whole area of RAM) Write A55A5AA5 and then read. (Whole area of RAM) Sub CPU normal RAM abnormal Write 5AA5 and then read. (Whole area of RAM) Write A55A and then read. (Whole area of RAM)

Threshold Value 5AA5A55A cannot be read. A55A5AA5 cannot be read. 5AA5 cannot be read. A55A cannot be read.

Time Needed for Diagnosis: Undetermined Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgment Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Main CPU normal RAM abnormal Write 5AA5A55A and then read. (Whole area of RAM) And write A55A5AA5 and then read. (Whole area of RAM) Sub CPU normal RAM abnormal Write 5AA5 and then read. (Whole area of RAM) And write A55A and then read. (Whole area of RAM)

Threshold Value 5AA5A55A can be read. A55A5AA5 can be read. 5AA5 can be read. A55A can be read.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CA:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR 1. OUTLINE OF DIAGNOSIS Judge as NG when SUM value of ROM is outside the standard value.

2. ENABLE CONDITION Secondary Parameters Ignition switch

Enable Conditions ON

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD Abnormality Judgment Judge as NG if the criteria below are met. Judgment Value Malfunction Criteria SUM value of ROM

Threshold Value Standard

Time Needed for Diagnosis: Undetermined Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CB:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Judge as NG when any one of the followings is established. (1) Monitoring IC operates abnormally. (Monitoring IC malfunction) (2) Input amplifier circuit of throttle position sensor 1 operates abnormally. (fourfold amplifier malfunction) (3) CPU operates abnormally. (Instruction/flow check) (4) A/D converter operates abnormally. (ADC malfunction) (5) EEPROM operates abnormally. (EEPROM malfunction) (6) Output IC operates abnormally. (Output driver malfunction)

2. COMPONENT DESCRIPTION

(1)

(9)

(8)

(12)

(7)

(10) (7)

(2)

(3)

(4)

(7) (13)

(5)

(11)

(7)

(6)

EN-08016

(1)

Throttle position sensor

(6)

(2) (3) (4) (5)

Throttle position sensor 1 Throttle position sensor 2 Accelerator pedal position sensor Accelerator pedal position sensor 1

(7) (8) (9)

Accelerator pedal position sensor 2 I/F circuit Amplifier circuit Engine control module (ECM)

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(10)

CPU

(11) (12) (13)

Monitoring IC EEPROM Output IC

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters (1) Battery voltage (2) Ignition switch (2) Battery voltage (3) Ignition switch (3) ETC control (4) Ignition switch (4) Battery voltage (5) Starter switch (5) Battery voltage (6) Ignition switch (6) Battery voltage

Enable Conditions ≥6V ON ≥6V ON Permitted ON ≥6V OFF >6V ON ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria (1) Monitoring IC operation

Threshold Value The result and estimated value match. 1: Lean λ < 1: Rich

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1)

Atmosphere

(3)

ZrO2

(4)

Ceramic heater

(2)

Exhaust gas

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Barometric pressure Rear oxygen sensor sub feedback Rear oxygen sensor output voltage – Feedback target voltage or rear oxygen sensor sub feedback compensation coefficient or rear oxygen sensor sub feedback compensation coefficient Elapsed time after starting the engine Engine coolant temperature Vehicle speed Amount of intake air Load change at 180°CA Front oxygen (A/F) sensor impedance Learning value of evaporation gas density Total time of operating canister purge Targeted lambda value load compensation coefficient

Enable Conditions ≥ 4096 ms ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) Execution –0.2 V — 0.1 V On Min. On Max. ≥ 60000 ms ≥ 75 °C (167 °F) ≥ 20 km/h (12.4 MPH) ≥ 6 g/s (0.21 oz/s) < 0.02 g/rev (0 oz/rev) 0 Ω — 50 Ω < 0.2 ≥ 19.9 s –0.03 — 0.000

4. GENERAL DRIVING CYCLE Perform diagnosis continuously at a constant speed of 20 km/h (12.4 MPH) or more after 60000 ms have passed since the engine started.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria λ value

Threshold Value < 0.85

Time Needed for Diagnosis: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria λ value

Threshold Value ≥ 0.85

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CJ:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1) 1. OUTLINE OF DIAGNOSIS Detect that λ value remains high. Judge as NG when lambda value is abnormal in accordance with λ value of front oxygen (A/F) sensor and running conditions such as vehicle speed, amount of intake air, engine coolant temperature, sub feedback control, etc. λ value = Actual air fuel ratio/Theoretical air fuel ratio λ > 1: Lean λ < 1: Rich

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1)

Atmosphere

(3)

ZrO2

(4)

Ceramic heater

(2)

Exhaust gas

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Barometric pressure Rear oxygen sensor sub feedback Rear oxygen sensor output voltage – Feedback target voltage or rear oxygen sensor sub feedback compensation coefficient or rear oxygen sensor sub feedback compensation coefficient Elapsed time after starting the engine Engine coolant temperature Vehicle speed Amount of intake air Load change at 180°CA Front oxygen (A/F) sensor impedance Learning value of evaporation gas density Total time of operating canister purge Targeted lambda value load compensation coefficient

Enable Conditions ≥ 4096 ms ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) Execution –0.2 V — 0.1 V On Min. On Max. ≥ 60000 ms ≥ 75 °C (167 °F) ≥ 20 km/h (12.4 MPH) ≥ 6 g/s (0.21 oz/s) < 0.02 g/rev (0 oz/rev) 0 Ω — 50 Ω < 0.2 ≥ 19.9 s –0.03 — 0.000

4. GENERAL DRIVING CYCLE Perform diagnosis continuously at a constant speed of 20 km/h (12.4 MPH) or more after 60000 ms have passed since the engine started.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria λ value

Threshold Value > 1.15

Time Needed for Diagnosis: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria λ value

Threshold Value ≤ 1.15

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CK:DTC P1160 RETURN SPRING FAILURE 1. OUTLINE OF DIAGNOSIS Judge as NG when the valve is opened more than the default opening angle, but does not move to the close direction with the motor power stopped.

2. COMPONENT DESCRIPTION

(1)

(8)

S S (7)

(3) (6) (2) (4)

(5)

EN-01866

(1) (2) (3)

Opener spring Return spring Intermediate stopper

(4) (5) (6)

Full closed stopper Throttle valve Gear

(7) (8)

DC motor Main and sub throttle sensor

3. ENABLE CONDITION Secondary Parameters Motor continuity

Enable Conditions OFF

4. GENERAL DRIVING CYCLE • Ignition switch ON → OFF • Ignition switch OFF → ON (Only after clearing memory)

5. DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Opening variation after continuity is set to OFF

Threshold Value ≥ 2°

Time Needed for Diagnosis:1880 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CL:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM 1. OUTLINE OF DIAGNOSIS Detect the abnormal function (stuck closed) of the drain valve. Judge as NG when fuel tank pressure is low.

2. COMPONENT DESCRIPTION (19)

(14)

(9)

(10)

(15)

(11)

(16)

(12)

(8)

(13)

(7)

(17)

(4)

(2)

(5)

(19)

(6)

(1)

(18)

(3) EN-02294

(1) (2) (3) (4) (5) (6) (7)

Bobbin Coil Diode Stator core End plate Body Yoke

(8) (9) (10) (11) (12) (13)

Magnetic plate Shaft Plate Valve Housing Filter

3. ENABLE CONDITION Secondary Parameters Drain valve Battery voltage Barometric pressure Tank pressure when starter is OFF → ON

Enable Conditions Open ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) –0.4 kPa (–3.2 mmHg, –0.1 inHg) and 1.4 kPa (10.7 mmHg, 0.4 inHg)

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(14) (15) (16) (17) (18) (19)

Retainer Diaphragm Movable core Spring Cover O-ring

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Fuel tank pressure

Threshold Value ≤ –4 kPa (–30 mmHg, –1.2 inHg)

Time Needed for Diagnosis: 3000 s Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Fuel tank pressure Cumulative time when all the malfunction criteria below are met. Purge control solenoid valve duty Fuel temperature Intake manifold relative pressure

Threshold Value > –4 kPa (–30 mmHg, –1.2 inHg) ≥ 30000 s Not = 0 –10 °C (14 °F) — 70 °C (158 °F) ≥ –26.7 kPa (–200 mmHg, –7.9 inHg)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CM:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) 1. OUTLINE OF DIAGNOSIS • Detects open or short circuit of EGR. • Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (5)

(1) (6)

(3) (2) (4)

EN-02051

(1) (2)

Engine control module (ECM) Computer unit (CPU)

(3) (4)

Detecting circuit Switch circuit

3. ENABLE CONDITION Secondary Parameters Elapsed time after starting the engine EGR valve target position Battery voltage

Enable Conditions ≥ 1 second > 0 step ≥ 10.9 V

4. GENERAL DRIVING CYCLE Perform diagnosis continuously during EGR operation.

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(5) (6)

Battery voltage Main relay

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Terminal voltage level when ECM outputs OFF signal or Terminal voltage level when EGR operates

Threshold Value Low level

Low level

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal voltage level when ECM outputs OFF signal Terminal voltage level when EGR operates

Threshold Value High level High level

Time Needed for Diagnosis: 256 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CN:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT) 1. OUTLINE OF DIAGNOSIS • Detects open or short circuit of EGR. • Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (5)

(1) (6)

(3) (2) (4)

EN-02051

(1) (2)

Engine control module (ECM) Computer unit (CPU)

(3) (4)

Detecting circuit Switch circuit

3. ENABLE CONDITION Secondary Parameters Elapsed time after starting the engine EGR valve target position Battery voltage

Enable Conditions ≥ 1 second > 0 step ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(5) (6)

Battery voltage Main relay

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Terminal voltage level when ECM outputs ON signal or Terminal voltage level when EGR operates

Threshold Value High level

High level

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal voltage level when ECM outputs ON signal Terminal voltage level when EGR operates

Threshold Value Low level Low level

Time Needed for Diagnosis: 256 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CO:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1492.

CP:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1493.

CQ:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1492.

CR:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1493.

CS:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1492.

CT:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1493.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CU:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of starter SW. Judge as OFF NG when it becomes after engine start despite no starter ON experience.

2. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment Judge as OFF NG when the following conditions are established. Judgment Value Malfunction Criteria Vehicle speed Starter ON signal Engine condition Battery voltage

Threshold Value < 1 km/h (0.6 MPH) Not detected Changed from before start to after start ≥8V

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OFF OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Starter ON Starter ON diagnosis Battery voltage

Threshold Value Experienced No diagnosis experience ≥8V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CV:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION 1. OUTLINE OF DIAGNOSIS Detect the open/short circuit of back-up power supply circuit. Judge as NG when the backup power voltage is low.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Voltage of back-up power supply Battery voltage Engine condition

Threshold Value Low ≥ 10.9 V After engine starting

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Voltage of back-up power supply Battery voltage Engine condition

Threshold Value High ≥ 10.9 V After engine starting

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CW:DTC P1570 ANTENNA 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

CX:DTC P1571 REFERENCE CODE INCOMPATIBILITY 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

CY:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

CZ:DTC P1574 KEY COMMUNICATION FAILURE 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

DA:DTC P1576 EGI CONTROL MODULE EEPROM 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

DB:DTC P1577 IMM CONTROL MODULE EEPROM 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

DC:DTC P1578 METER FAILURE 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DD:DTC P1602 CONTROL MODULE PROGRAMMING ERROR 1. OUTLINE OF DIAGNOSIS Detect malfunctions of the catalyst advanced idling retard angle control. Judge as NG when ECM is not controlling the angle properly during catalyst advanced idling retard angle control. Judge as NG if there is exhaust gas temperature diagnosis, idle speed diagnosis and final ignition timing diagnosis, and if any one of them is NG. • Exhaust temperature diagnosis Judge as NG when the estimated exhausted gas temperature in 14 seconds after the cold start is below the specified value. • Idle speed diagnosis Judge as NG when actual engine speed is not close to target engine speed after terminating the retard angle control. • Final ignition timing diagnosis Judge as NG when actual retard amount is under the specified value at cold start.

2. ENABLE CONDITION Secondary Parameters Atmospheric pressure Battery voltage Cold start diagnosis Vehicle speed Misfire in 200 engine revs. Elapsed time after starting the engine

Enable Conditions ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 10.9 V Incomplete < 2 km/h (1.2 MPH) –300 rpm) Continuous time of (actual retard amount > 30 °CA)

Threshold Value ≥ 6000 ms ≥ 0 ms

Time Needed for Diagnosis: 14 seconds Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Continuous time of (Target engine speed – Actual engine speed > –300 rpm) Continuous time of (actual retard amount > 30 °CA)

Threshold Value < 6000 ms < 0 ms

Time Needed for Diagnosis: Less than 1 second • Final ignition timing diagnosis Abnormality Judgment Judge as NG when the following conditions are established with diagnosis enable conditions successful. Judgment Value Malfunction Criteria Duration time of (Standard ignition timing – Actual ignition timing ≤ 0 °CA)

Threshold Value > 5000 ms

Time Needed for Diagnosis: 5000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Duration time of (Standard ignition timing – Actual ignition timing > 0 °CA)

Threshold Value > 1000 ms

Time Needed for Diagnosis: 1000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DE:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of fuel system from the size of the sub feedback learning value. Control the sub feedback learning and judge as NG when the learning value is in the lean zone.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

3. ENABLE CONDITION Secondary Parameters Conditions for carrying out the sub feedback learning Continuous time when all conditions are established.

Enable Conditions Completed ≥1s

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km/h (50 MPH) or more.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sub feedback learning value

Threshold Value < –0.032

Time Needed for Diagnosis: 5 s × 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sub feedback learning value

Threshold Value ≥ –0.032 + 0

Time Needed for Diagnosis: 5 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DF:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of fuel system from the size of the sub feedback learning value. Sub feedback learning is being performed. When the learning value goes to the rich side, judge as NG.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

3. ENABLE CONDITION Secondary Parameters Conditions for carrying out the sub feedback learning Continuous time when all conditions are established.

Enable Conditions Completed ≥1s

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km/h (50 MPH) or more.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sub feedback learning value

Threshold Value ≥ 0.032 (PZEV model) ≥ 0.02 (except for PZEV model)

Time Needed for Diagnosis: 5 s × 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sub feedback learning value

Threshold Value < 0.032 + 0 (PZEV model) < 0.02 + 0 (except for PZEV model)

Time Needed for Diagnosis: 5 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DG:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE 1. OUTLINE OF DIAGNOSIS Judge as NG when the motor current becomes large or drive circuit is heated.

2. COMPONENT DESCRIPTION 12V

12V

(1)

(6)

(2)

(3)

(7)

(4)

(2)

(5) EN-01867

(1) (2) (3)

Engine control module (ECM) Detecting circuit Overcurrent detection circuit

(4) (5)

Drive circuit Temperature detection circuit

(6) (7)

Electronic throttle control relay Motor

3. ENABLE CONDITION Secondary Parameters Under control of electronic throttle control

Enable Conditions ON

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Motor current Drive circuit inner temperature

Threshold Value ≤8A ≤ 175°C (347°F)

Time Needed for Diagnosis: • 500 ms (NG judgment) • 2000 ms (OK judgment) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DH:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Judge as NG when the electronic throttle control power is not supplied even when ECM sets the electronic throttle control relay to ON.

2. COMPONENT DESCRIPTION 12V

12V

(1)

(4)

(2)

(5)

(3)

EN-01868

(1) (2)

Engine control module (ECM) Voltage detection circuit

(3) (4)

Drive circuit Electronic throttle control relay

(5)

Motor

3. ENABLE CONDITION Secondary Parameters Electronic throttle control relay output

Enable Conditions ON

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Motor power voltage

Threshold Value ≥5V

Time Needed for Diagnosis: • 400 ms (NG judgment) • 2000 ms (OK judgment) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DI: DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Judge as NG when the electronic throttle control power is supplied even when ECM sets the electronic throttle control relay to OFF.

2. COMPONENT DESCRIPTION 12V

12V

(1)

(4)

(2)

(5)

(3)

EN-01868

(1) (2)

Engine control module (ECM) Voltage detection circuit

(3) (4)

Drive circuit Electronic throttle control relay

(5) Motor

3. ENABLE CONDITION Secondary Parameters Electronic throttle control relay output

Enable Conditions OFF

4. GENERAL DRIVING CYCLE • When ignition switch ON → OFF • Ignition switch OFF → ON (Only after clearing memory)

5. DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Motor power voltage

Threshold Value ≤5V

Time Needed for Diagnosis: • 600 ms (NG judgment) • 400 ms (OK judgment) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DJ:DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP PERFORMANCE 1. OUTLINE OF DIAGNOSIS Judge as NG when full close point learning cannot conducted or abnormal value is detected.

2. COMPONENT DESCRIPTION

(1)

(3)

(2)

(4)

EN-01869

(1) (2)

Engine control module (ECM) Drive circuit

(3)

Motor

(4)

Throttle position sensor

3. ENABLE CONDITION Secondary Parameters Ignition switch Ignition switch (only after clear memory)

Enable Conditions ON → OFF OFF → ON

4. GENERAL DRIVING CYCLE Perform the diagnosis at full closed point learning.

5. DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Throttle sensor opening angle at full close point learning Throttle opening angle when the ignition switch is ON – Throttle minimum stop position

Threshold Value 10.127° or more, 19.872° or less ≥ 1.683°

Time Needed for Diagnosis: 8 — 80 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DK:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-183

(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value < 0.217 V

Time Needed for Diagnosis: 100 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value ≥ 0.217 V

Time Needed for Diagnosis: 100 ms

GD(H4SO)-184

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DL:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-185

(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value ≥ 4.783 V

Time Needed for Diagnosis: 32 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value < 4.783 V

Time Needed for Diagnosis: 32 ms

GD(H4SO)-186

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DM:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-187

(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value < 0.217 V

Time Needed for Diagnosis: 100 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value ≥ 0.217 V

Time Needed for Diagnosis: 100 ms

GD(H4SO)-188

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DN:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-189

(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value ≥ 4.783 V

Time Needed for Diagnosis: 100 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value < 4.783 V

Time Needed for Diagnosis: 100 ms

GD(H4SO)-190

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DO:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION 1. OUTLINE OF DIAGNOSIS Judge as NG when the signal level of throttle position sensor 1 is different from the throttle position sensor 2.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-191

(4)

Engine control module (ECM)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the NG range of judgment value detail

Details of Judgment Value

(Y5)

(NG area)

(Y4) Sensor output difference (˚)

(Y3) (Y2) (OK area)

(Y1)

0 0 (X1) (X2)

(X3)

(X4)

Throttle position sensor 1 opening angle (˚)

EN-08032

(X1) (X4)

2.125 ° 31.625 °

(X2)

4.25 °

(X3)



(Y1) (Y4)

5.15 ° 10.4 °

(Y2) (Y5)

6.15 ° 12.4 °

(Y3)

8.28 °

Time Needed for Diagnosis: 212 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the OK range of judgment value detail

Time Needed for Diagnosis: 24 ms

GD(H4SO)-192

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DP:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION 1. OUTLINE OF DIAGNOSIS Judge as NG when the signal level of throttle position sensor 1 is different from the throttle position sensor 2.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4SO)-193

(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the NG range of judgment value detail

Details of Judgment Value

(Y5)

(Y4) Sensor output difference (˚)

(NG area)

(Y3) (Y2) (Y1) (OK area)

0 0

(X1)

(X2)

(X3)

(X4)

Accelerator pedal position sensor 1 opening angle (˚) EN-08033

(X1) (X4)

0.6 ° 4°

(X2)

1.2 °

(X3)



(Y1) (Y4)

1.465 ° 2.455 °

(Y2) (Y5)

1.597 ° 3.116 °

(Y3)

1.663 °

Time Needed for Diagnosis: 116 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the OK range of judgment value detail

Time Needed for Diagnosis: 116 ms

GD(H4SO)-194

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DQ:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect the malfunction of barometric pressure sensor output property. Judge as NG when the barometric pressure sensor output is largely different from the intake manifold pressure at engine start.

2. COMPONENT DESCRIPTION The barometric pressure sensor is built into the ECM.

3. ENABLE CONDITION Secondary Parameters Engine speed Vehicle speed

Enable Conditions < 300 rpm < 1 km/h (0.6 MPH)

4. GENERAL DRIVING CYCLE Perform the diagnosis once at ignition switch ON.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria |Barometric pressure – Intake manifold pressure| |Intake manifold pressure at engine start – Intake manifold pressure|

Threshold Value ≥ 26.7 kPa (200 mmHg, 7.9 inHg) < 1.3 kPa (9.99 mmHg, 0.4 inHg)

Time Needed for Diagnosis: 328 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria |Barometric pressure – Intake manifold pressure|

Threshold Value < 26.7 kPa (200 mmHg, 7.9 inHg)

Time Needed for Diagnosis: 262 ms

GD(H4SO)-195

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DR:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open/short circuit of the barometric pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION The barometric pressure sensor is built into the ECM.

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 1.707 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 1.707 V

Time Needed for Diagnosis: Less than 1 second

GD(H4SO)-196

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DS:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open/short circuit of the barometric pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION The barometric pressure sensor is built into the ECM.

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.234 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.234 V

Time Needed for Diagnosis: Less than 1 second

GD(H4SO)-197

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DT:DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION 1. OUTLINE OF DIAGNOSIS Detect malfunction of CAN communication. When CAN communications is not possible, and CAN communications with TCM, VDC CM and body integrated unit is not possible, judge as NG if data from the TCM, VDC CM and body integrated unit are not normal.

2. COMPONENT DESCRIPTION ECM, TCM, VDC CM and body integrated unit are connected by high speed CAN.

(Common Specifications) CAN Protocol 2.0 B (Active) Frame Format: 11 Bit ID Frame (Standard Frame) (High speed CAN) Conforms to ISO11898 Communication Speed: 500 kbps

3. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting the engine.

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Battery voltage Starter switch Engine bus off flag or error warning flag or ID received from control module connected to driving system CAN or Data updated from control module connected to driving system CAN

Threshold Value > 10.9 V OFF run set (error) None during 500 milliseconds None during 2000 milliseconds

Time Needed for Diagnosis: 2 seconds Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria

Threshold Value

Battery voltage Starter switch Engine bus off flag or error warning flag ID received from control module connected to driving system CAN Data updated from control module connected to driving system CAN

> 10.9 V OFF run clear (No error) Yes Yes

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

GD(H4SO)-198

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DU:DTC U0101 CAN (TCU) DATA NOT LOADED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

DV:DTC U0122 CAN (VDC) DATA NOT LOADED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

DW:DTC U0140 CAN (BCU) DATA NOT LOADED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

DX:DTC U0402 CAN (TCU) DATA ABNORMAL 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

DY:DTC U0416 CAN (VDC) DATA ABNORMAL 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

DZ:DTC U0422 CAN (BCU) DATA ABNORMAL 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

GD(H4SO)-200

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2010 LEGACY SERVICE MANUAL

QUICK REFERENCE INDEX

ENGINE 2 SECTION

This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of 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.

FUEL INJECTION (FUEL SYSTEMS)

FU(H4DOTC)

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(H4DOTC)

INTAKE (INDUCTION)

IN(H4DOTC)

MECHANICAL

ME(H4DOTC)

EXHAUST

EX(H4DOTC)

COOLING

CO(H4DOTC)

LUBRICATION

LU(H4DOTC)

SPEED CONTROL SYSTEMS

SP(H4DOTC)

IGNITION

IG(H4DOTC)

STARTING/CHARGING SYSTEMS

SC(H4DOTC)

ENGINE (DIAGNOSTICS)

EN(H4DOTC) (diag)

GENERAL DESCRIPTION

GD(H4DOTC)

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD.

G2460BE3

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FUEL INJECTION (FUEL SYSTEMS)

FU(H4DOTC) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

Page General Description ...................................................................................2 Throttle Body ............................................................................................15 Intake Manifold .........................................................................................17 Engine Coolant Temperature Sensor .......................................................32 Crankshaft Position Sensor ......................................................................33 Camshaft Position Sensor ........................................................................35 Knock Sensor ...........................................................................................37 Throttle Position Sensor ...........................................................................39 Mass Air Flow and Intake Air Temperature Sensor .................................40 Manifold Absolute Pressure Sensor .........................................................41 Fuel Injector .............................................................................................43 Tumble Generator Valve Assembly .........................................................46 Tumble Generator Valve Actuator ............................................................48 Oil Flow Control Solenoid Valve ...............................................................49 Wastegate Control Solenoid Valve ..........................................................51 Front Oxygen (A/F) Sensor ......................................................................53 Rear Oxygen Sensor ................................................................................55 Engine Control Module (ECM) .................................................................57 Main Relay ...............................................................................................58 Fuel Pump Relay ......................................................................................60 Electronic Throttle Control Relay .............................................................62 Fuel Pump Control Unit ............................................................................64 Fuel ..........................................................................................................65 Fuel Tank .................................................................................................67 Fuel Filler Pipe .........................................................................................74 Fuel Pump ................................................................................................78 Fuel Level Sensor ....................................................................................80 Fuel Sub Level Sensor .............................................................................82 Fuel Filter .................................................................................................84 Fuel Damper ............................................................................................86 Fuel Delivery, Return and Evaporation Lines ...........................................87 Fuel System Trouble in General ..............................................................92

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General Description FUEL INJECTION (FUEL SYSTEMS)

1. General Description A: SPECIFICATION Fuel tank

Fuel pump

Capacity Install locations Type Shutoff discharge pressure Discharge rate

Fuel filter

70 2 (18.5 US gal, 15.4 Imp gal) Under rear seat Impeller 850 kPa (8.67 kgf/cm2, 123.3 psi) or less 175 2 (46.2 US gal, 38.5 Imp gal)/h or more. [12 V at 300 kPa (3.06 kgf/cm2, 43.5 psi)] In-tank type

FU(H4DOTC)-2

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General Description FUEL INJECTION (FUEL SYSTEMS)

B: COMPONENT 1. INTAKE MANIFOLD 1 A

T8

T6 (2)

T2

(3)

T4

T5

(1)

(13)

(4)

(4)

(7)

(15)

(9)

(14)

(12)

(9)

(9)

D

(17)

(22)

B

E

(21) T1

(10)

(24) (12)

(18)

T4

(8)

F

(16)

H

G

C

T4

C T7

T2

(6)

T6

(5)

(11)

(25) (19)

T1

(23)

(20) T4

T4 T1

D

I

T7 A

(28)

H

(24) (25) (24)

F

E (27)

I

T1

T7 (24)

(35)

T4 T7

(31)

(36)

T7

T7

(26)

(25)

T9

(32) (33) (34)

T1

G

(32) (33) (34)

(28)

(24)

T4 T1

(29)

(30) B

(37)

T9

(24)

(31) (32)

T3 (33) (34)

(38)

T7

(40)

(39)

(37)

(38)

T7

T7

(39) FU-04942

FU(H4DOTC)-3

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General Description FUEL INJECTION (FUEL SYSTEMS) (1) (2)

Intake manifold Vacuum control hose

(18) (19)

Vacuum hose C Filter

(35) (36)

PCV pipe Intake manifold protector RH

(3)

PCV valve

(20)

Vacuum hose D

(37)

Tumble generator valve ASSY

(4)

Clamp

(21)

Purge control solenoid valve 2

(38)

Gasket

(5)

Intake duct

(22)

Vacuum hose E

(39)

Knock pin

(6) (7)

Throttle body O-ring

(23) (24)

Vacuum hose F Clamp

(40)

Intake manifold protector LH

(8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

Preheater hose A Clip Preheater hose B Pressure regulator vacuum hose O-ring Purge control solenoid valve 1 Vacuum hose A Vacuum hose B Solenoid valve bracket Manifold absolute pressure sensor

(25) (26) (27) (28) (29) (30) (31) (32) (33) (34)

Fuel hose A Fuel delivery pipe Fuel hose B Fuel pipe O-ring Pressure regulator O-ring Grommet Fuel injector Seal ring

Tightening torque:N·m (kgf-m, ft-lb) T1: 1.25 (0.1, 0.9) T2: 3 (0.3, 2.2) T3: 3.45 (0.4, 2.5) T4: 6.4 (0.7, 4.7) T5: 8 (0.8, 5.9) T6: 8.3 (0.8, 6.1) T7: 19 (1.9, 14.0) T8: 23 (2.3, 17.0) T9: 25 (2.5, 18.4)

FU(H4DOTC)-4

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General Description FUEL INJECTION (FUEL SYSTEMS)

2. INTAKE MANIFOLD 2

(1)

(2)

T1

T2

(4) (3)

T1 (5) (7) (8)

(6) (7)

FU-04943

(1) (2) (3) (4)

Intake manifold Engine harness Vacuum hose A PCV pipe

(5) (6) (7) (8)

Vacuum hose B Vacuum hose C Clip Brake booster vacuum hose

FU(H4DOTC)-5

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 19 (1.9, 14.0)

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General Description FUEL INJECTION (FUEL SYSTEMS)

3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS T1

(4)

T2

T1 T1

(3)

(1)

(2)

(6)

T1

(5)

T1 (7)

T1 T1

T1 FU-04844

(1)

Crankshaft position sensor

(5)

Exhaust camshaft position sensor LH

(2)

Knock sensor

(6)

Exhaust camshaft position sensor RH

T1: 6.4 (0.7, 4.7)

(3)

Intake camshaft position sensor LH Intake camshaft position sensor RH

(7)

Engine harness cover

T2: 24 (2.4, 17.7)

(4)

FU(H4DOTC)-6

Tightening torque:N·m (kgf-m, ft-lb)

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General Description FUEL INJECTION (FUEL SYSTEMS)

4. FUEL TANK (23)

T1

(8)

T1 T1

A

(7)

(14)

B

C (24)

(24)

(9)

(12)

(10) (1) D

(11)

(15)

(25)

(13)

(24) T4 (2)

C (3)

B T4

(16) (16)

(17)

T4

(6)

(16)

(16) A

T3

D

T3 (4)

T3 (18) (19)

(20)

T2 (22) T2

(16)

(22)

(21)

T3

(5)

(22)

T2

(22) T2

T3

FU-04944

FU(H4DOTC)-7

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General Description FUEL INJECTION (FUEL SYSTEMS) (1) (2)

Fuel tank Fuel tank band RH

(12) (13)

Fuel sub level sensor upper plate Fuel sub level sensor gasket

(23) (24)

Rubber cap Cushion

(3) (4)

Fuel tank band LH Fuel delivery tube

(14) (15)

Fuel sub level sensor protector Fuel sub level sensor filter

(25)

Cushion

(5) (6) (7) (8) (9) (10)

Fuel return tube Fuel sub delivery tube Fuel pump ASSY Fuel pump upper plate Fuel pump gasket Fuel sub level sensor upper plate cushion Fuel sub level sensor

(16) (17) (18) (19) (20) (21)

Retainer Stopper Heat shield cover Fuel tank protector RH Fuel tank protector LH Clip

Tightening torque:N·m (kgf-m, ft-lb) T1: 4.4 (0.4, 3.2) T2: 9 (0.9, 6.6) T3: 18 (1.8, 13.3) T4: 33 (3.4, 24.3)

(22)

Self-locking nut

(11)

FU(H4DOTC)-8

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General Description FUEL INJECTION (FUEL SYSTEMS)

5. FUEL LINE (25) (28) T3

(27) G

(40) (44)

(1) (1)

(1)

(41) (1)

(43)

F

(1)

T2

(39)

F I

(35)

(24)

(1)

D

(32) (1)

(30)

F (1) (29)

(1) (38)

(1) (1)

(37) (33)

(42)

(22)

(26)

H

(36)

(23)

T2

(34)

(36)

T5 E

I G

(21) T3

F

D

(31) (1) (29) H

(18) (1) (16) (17) (16) C

(16)

F

E

(1)

(45)

(20)

(19)

(16) (15)

T3

T3 (14) (5)

T1

T1

(9)

(1)

(7)

C (1) (13)

(11)

(11) (1)

(6) (4)

(1)

A

(5) B

(12) (3)

(9)

(11)

(2)

T1

T1

A

(11) B

T4

(8)

(10) FU-04945

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General Description FUEL INJECTION (FUEL SYSTEMS) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)

Clip Fuel return hose A Fuel return hose B Evaporation hose Connect check cover Fuel delivery hose A Fuel delivery hose B Fuel damper holder Fuel damper Fuel damper bracket Clamp Fuel pipe ASSY Purge hose A Purge pipe Air vent hose A

(19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33)

Connector PCV drain tube Vent tube Drain valve Drain filter Canister Canister protector Charge tube Canister drain tube Drain tube ASSY Connector PCV drain hose PCV outlet hose Pressure control solenoid valve Pressure control solenoid valve bracket A

(16)

Clip

(34)

(17) (18)

Connector Air vent hose B

(35) (36)

Pressure control solenoid valve bracket B PCV inlet hose Clamp

FU(H4DOTC)-10

(37) (38) (39) (40) (41) (42) (43) (44) (45)

Fuel filler hose Charge hose Circulate hose Circulate tube Pressure hose Fuel tank pressure sensor bracket Vacuum hose Fuel tank pressure sensor Purge hose B

Tightening torque:N·m (kgf-m, ft-lb) T1: 1.25 (0.1, 0.9) T2: 2.5 (0.3, 1.8) T3: 7.35 (0.7, 5.4) T4: 7.5 (0.8, 5.5) T5: 8 (0.8, 5.9)

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General Description FUEL INJECTION (FUEL SYSTEMS)

6. FUEL FILLER PIPE (3)

(10)

(1)

T2

(2) (4)

(11) (12) (5) (14)

(11)

(6)

(15)

T4 (13)

A T4

(14) (16)

(7)

(17)

A

(18)

T4 (8)

T3

T4

T1

(8)

B B

(9)

(19) T4 FU-04946

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Fuel filler cap Fuel filler pipe protector Clip Neck holder A Neck holder B Fuel filler pipe Fuel filler pipe bracket A Fuel filler pipe bracket B Fuel filler pipe bracket C

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Shut valve Clip Evaporation hose A Evaporation pipe A Clip Evaporation hose B Grommet Evaporation pipe B Evaporation pipe protector

FU(H4DOTC)-11

(19)

Grommet

Tightening torque:N·m (kgf-m, ft-lb) T1: 1 (0.1, 0.7) T2: 4.5 (0.5, 3.3) T3: 7.35 (0.7, 5.4) T4: 7.5 (0.8, 5.5)

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General Description FUEL INJECTION (FUEL SYSTEMS)

7. FUEL PUMP (1) B (3)

A

B

(4)

(2) (2)

(5)

A (6)

A (7)

(11)

(10)

(8)

(11) (9)

FU-08403

(1)

Fuel filter assembly

(5)

Fuel pump

(9)

(2)

Pump module spring

(6)

Support rubber cushion

(10)

(3) (4)

Fuel pump harness Gasket spacer

(7) (8)

Fuel pump holder Fuel chamber ASSY

(11)

FU(H4DOTC)-12

Fuel level sensor (model with fuel level sensor bent in 3 locations) Fuel level sensor (model with fuel level sensor bent in 2 locations) Fuel temperature sensor

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General Description FUEL INJECTION (FUEL SYSTEMS)

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. • Place “NO OPEN FLAMES” signs near the working area. • Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing fuel.

FU(H4DOTC)-13

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General Description FUEL INJECTION (FUEL SYSTEMS)

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 18371AA000

DESCRIPTION CONNECTOR REMOVER

REMARKS Used for disconnecting the quick connector on the fuel return hose of the engine compartment (intake manifold).

18471AA000

FUEL PIPE ADAPTER

Used for draining fuel.

42099AE000

QUICK CONNECTOR RELEASE

Used for disconnecting quick connector of the engine compartment.

1B022XU0

SUBARU SELECT MONITOR III KIT

Used for draining fuel and each inspection.

ST18371AA000

ST18471AA000

ST42099AE000

ST1B022XU0

2. GENERAL TOOL TOOL NAME Circuit tester Oscilloscope Sensor socket

REMARKS Used for measuring resistance and voltage. Used for inspecting the waveform of each sensor. Used for removing and installing the front oxygen (A/F) sensor and rear oxygen sensor.

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Throttle Body FUEL INJECTION (FUEL SYSTEMS)

2. Throttle Body

9) Remove the bolts which secure the throttle body to the intake manifold, and remove the throttle body.

A: REMOVAL 1) Remove the collector cover. 2) Disconnect the ground cable from battery.

FU-04954

IG-02107

3) Lift up the vehicle. 4) Remove the under cover. 5) Drain approximately 2.0 2 (2.1 US qt, 1.8 Imp qt) of engine coolant. 6) Remove the intercooler. 7) Remove the bolts which secure the engine harness and PCV pipe to the intake manifold, and remove the intake duct from the throttle body.

B: INSTALLATION Install in the reverse order of removal. NOTE: • Use new O-rings. • When installing the intake duct to the throttle body, align the protrusion (a) on the intake duct to the installation position mark (b) on the throttle body to install. (b)

(a)

FU-04706

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb) FU-04952

8) Disconnect the connectors and preheater hoses from the throttle position sensor.

FU-04954

FU-04953

FU(H4DOTC)-15

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Throttle Body FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: T1: 3 N·m (0.3 kgf-m, 2.2 ft-lb) T2: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

Throttle sensor

T1

Main T2

C: INSPECTION 1. THROTTLE SENSOR INSPECTION (METHOD WITH CIRCUIT TESTER) 1) Remove the glove box lid assembly. 2) Turn the ignition switch to ON. (engine OFF) 3) Check the voltage between ECM connector terminals.

Standard Approx. 0.6 V

18 (+) and 29 (–)

2. THROTTLE SENSOR INSPECTION (METHOD WITH SUBARU SELECT MONITOR) 1) Turn the ignition switch to ON. (engine OFF) 2) Read the throttle opening angle signal and voltage of throttle sensor using Subaru Select Monitor.

Throttle sensor

Throttle opening angle signal

Standard

Main

0.0 % 100.0 %

Approx. 0.6 V Approx. 4.04 V

Sub

0.0 % 100.0 %

Approx. 1.48 V Approx. 4.23 V

FU-04956 (A)

7 6 5 4 3 17 16 15 14 13 12 11 27 26 25 24 23 22 21 34 33 32 31

Terminal No.

Depressed Approx. 4.04 V (Full opened) Not depressed Approx. 1.48 V (Full closed) 28 (+) and 29 (–) Depressed Approx. 4.23 V (Full opened)

Sub

FU-04955

Accelerator pedal Not depressed (Full closed)

2 1 10 9 8 20 19 18 30 29 28

V FU-04049

(A) To ECM connector

FU(H4DOTC)-16

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

3. Intake Manifold

10) Disconnect the connectors from wastegate control solenoid valve, and remove the clip (A) which secure the engine harness.

A: REMOVAL 1) Remove the collector cover. 2) Collect the refrigerant from A/C system. 3) Release the fuel pressure. 4) Disconnect the ground cable from battery.

(A)

FU-04709

IG-02107

5) Open the fuel filler lid and remove the fuel filler cap. 6) Lift up the vehicle. 7) Remove the under cover. 8) Drain approximately 2.0 2 (2.1 US qt, 1.8 Imp qt) of engine coolant. 9) Disconnect the connectors from exhaust oil flow control solenoid valve (A) and exhaust camshaft position sensor (B). (A)

11) Lower the vehicle. 12) Remove the air intake duct. 13) Remove the intercooler. 14) Disconnect the A/C pressure hoses from A/C compressor. 15) Disconnect the vacuum control hose from the PCV valve.

FU-04957

16) Remove the bolts which secure the engine harness and PCV pipe to the intake manifold, and remove the intake duct from the throttle body.

(B)

(B) (A)

FU-04708

FU(H4DOTC)-17

FU-04952

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

17) Disconnect the preheater hose from throttle body.

20) Disconnect the vacuum hose from blow-by pipe, and remove the bolt securing the blow-by pipe to the intake manifold protector RH.

FU-04958

18) Disconnect the brake booster vacuum hose.

FU-04959

21) Disconnect vacuum hose (A) and vacuum control hose (B) from the PCV pipe. 22) Remove the nut securing the PCV pipe to the intake manifold protector RH, and move the PCV pipe in the forward direction of the vehicle.

(A) ME-04380

19) Disconnect the vacuum hose from rocker cover. (B) FU-04961

23) Disconnect the bulkhead harness connector from the engine harness connector (brown).

ME-04376

ME-04391

FU(H4DOTC)-18

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

24) Remove the bolt securing the bulkhead harness connector bracket, and disconnect the bulkhead harness connector from the engine harness connector (black).

28) Remove the clip which secure the generator cord to the intake manifold protector LH.

ME-04963 ME-04377

25) Remove the engine harness connector from the engine rear hanger.

29) Disconnect the connector from the knock sensor.

FU-05126 ME-04378

26) Disconnect the connectors from the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).

30) Disconnect the connector from the intake camshaft position sensor.

(A) (B) (C)

FU-04962

27) Disconnect the connectors from front oxygen (A/F) sensor (A) and rear oxygen sensor (B).

(B) (A) FU-04727

(A)

FU-04724

FU(H4DOTC)-19

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

31) Disconnect the connectors from the intake oil flow control solenoid valve.

34) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. (A)

ST

(B)

(C)

ME-04382

FU-04964

32) Disconnect the connector (A) from oil level switch. 33) Disconnect the connector (B) from ignition coil, and remove the clips (C) and bolt (D) securing the engine harness or oil level switch harness to the rocker cover.

(A) Fuel delivery hose (B) Fuel return hose (C) Evaporation hose

35) Disconnect the fuel return hose using the ST. ST 18371AA000 CONNECTOR REMOVER CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. (1) Attach ST to the fuel return pipe as shown in the figure.

(C) (B)

ST FU-03092

(A)

(D)

(B)

(C) FU-04965

FU(H4DOTC)-20

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

(2) Insert the front side of ST into the quick connector.

B: INSTALLATION 1) Install the intake manifold onto cylinder heads. NOTE: Use a new gasket.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

ST FU-03113

(3) Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose. FU-04966

2) Connect the fuel delivery hose, fuel return hose, and evaporation hose. NOTE: If fuel hoses or clamps are damaged, replace them with new parts. ST (A)

FU-03114

36) Remove the clip and disconnect the evaporation hose from the fuel pipe. (B)

(C)

FU-05059

(A) Fuel delivery hose (B) Fuel return hose (C) Evaporation hose FU-04611

37) Remove the intake manifold from cylinder head.

3) Connect the connector (A) from oil level switch. 4) Connect the connector (B) to ignition coil, and secure the engine harness or oil level switch harness to the rocker cover with clips (C) and bolt (D).

FU-04966

FU(H4DOTC)-21

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

6) Connect the connectors to the intake camshaft position sensor.

(C) (B)

(A)

(D)

(B)

(C) FU-04727

FU-04965

5) Connect the connectors to the intake oil flow control solenoid valve.

7) Connect the connector to the knock sensor.

FU-05126

8) Secure the generator cord to the intake manifold protector LH with a clip.

FU-04964

FU(H4DOTC)-22

ME-04963

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

9) Connect the connectors to front oxygen (A/F) sensor (A) and rear oxygen sensor (B).

13) Connect the bulkhead harness connector to the engine harness connector (brown).

(B) (A)

(A)

FU-04724

10) Connect the connector to the engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).

ME-04376

14) Install the nuts securing the PCV pipe to the intake manifold protector RH, and connect the vacuum hose (A) and vacuum control hose (B) to the PCV pipe.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(A) (B) (C)

(A)

FU-04962

11) Install the engine harness connector to the engine rear hanger.

(B) FU-04961

15) Install the blow-by pipe to the intake manifold protector RH, and connect vacuum hose to the blow-by pipe.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

ME-04378

12) Connect the bulkhead harness connector to the engine harness connector (black), and install the bolt securing the bulkhead harness connector bracket.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-04959

ME-04377

FU(H4DOTC)-23

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2015年12月24日 木曜日 午後5時18分

Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

16) Connect the vacuum hose to the rocker cover.

NOTE: When installing the intake duct to the throttle body, align the protrusion (a) on the intake duct to the installation position mark (b) on the throttle body to install. (b)

(a)

FU-04706

Tightening torque: T1: 3 N·m (0.3 kgf-m, 2.2 ft-lb) T2: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T1 T2 ME-04391

17) Connect the brake booster vacuum hose.

FU-04955

20) Connect the vacuum control hose to the PCV valve. ME-04380

18) Connect the preheater hoses to the throttle body.

FU-04957

FU-04958

19) Install the intake duct to the throttle body, and install the bolts which secure the engine harness and PCV pipe to the intake manifold.

21) Install the A/C pressure hoses to A/C compressor. 22) Install the intercooler. 23) Install the air intake duct. 24) Lift up the vehicle.

FU(H4DOTC)-24

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

25) Connect the connectors to the wastegate control solenoid valve, and secure the engine harness with clip (A). (A)

30) Fill engine coolant. 31) Charge the A/C system with refrigerant. 32) Install the collector cover.

C: DISASSEMBLY 1) Remove the intake manifold protector RH from intake manifold. FU-04709

26) Connect the connectors to exhaust oil flow control solenoid valve (A) and exhaust camshaft position sensor (B). (A) FU-04967

(B)

2) Disconnect front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B) from the intake manifold protector LH, and also remove clip (C) which holds the engine harness.

(C)

(B) (A)

(A)

FU-04708

27) Install the under cover. 28) Lower the vehicle. 29) Connect the ground cable to battery.

(B)

FU-04735

3) Remove the engine ground terminal from the intake manifold protector LH, and remove the intake manifold protector LH from the intake manifold.

FU-04968

IG-02107

FU(H4DOTC)-25

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

4) Remove the filter assembly.

8) Disconnect the connectors from the throttle position sensor.

FU-04737

5) Disconnect the vacuum hose from the intake manifold and fuel delivery pipe.

FU-04741

9) Remove the throttle body from the intake manifold.

FU-04738

6) Disconnect the connector from the manifold absolute pressure sensor, and remove the solenoid valve bracket assembly from the intake manifold.

FU-04742

10) Disconnect the connector from the fuel injector and tumble generator valve assembly.

FU-04739

7) Disconnect the connectors from the purge control solenoid valves 1 and 2.

FU-04969 FU-04740

FU(H4DOTC)-26

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

11) Remove the brake booster vacuum hose from the clip (A), and remove PCV pipe (B) and engine harness (C) from the intake manifold. (A)

14) Remove the fuel injector.

(C)

(B)

FU-04970

12) Remove the bolts which secure the fuel delivery pipe assembly to the intake manifold, and disconnect the pressure regulator vacuum hose from the intake manifold.

FU-04747

15) Disconnect vacuum hose (A), vacuum control hose (B) and brake booster vacuum hose (C) from the intake manifold. FU-04971 (B)

13) Remove the bolt which secures the fuel pipe to the intake manifold. (C)

(A)

FU-04960

16) Remove the bolts which secure the fuel delivery pipe to the intake manifold, loosen the clamps which hold the fuel hose to the fuel delivery pipe, and remove the fuel delivery pipe and fuel pipe.

FU-04749 FU-04972

FU(H4DOTC)-27

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

17) Remove the nipple from the intake manifold.

D: ASSEMBLY 1) Install the tumble generator valve assembly onto intake manifold. NOTE: Use new O-rings.

Tightening torque: 8.3 N·m (0.8 kgf-m, 6.1 ft-lb)

FU-04750

18) Remove the tumble generator valve assembly from the intake manifold.

FU-04751

2) Apply liquid gasket to the nipple threads, and install the nipple to the intake manifold.

FU-04751

Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Tightening torque: 23 N·m (2.3 kgf-m, 17.0 ft-lb)

FU-04750

3) Set the fuel delivery pipe and fuel pipe, tighten the clamps which hold the fuel hose to the fuel delivery pipe, and install the fuel delivery pipe to the intake manifold.

FU(H4DOTC)-28

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: T1: 1.25 N·m (0.1 kgf-m, 0.9 ft-lb) T2: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

T1

T2

FU-04752

4) Connect vacuum hose (A), vacuum control hose (B) and brake booster vacuum hose (C) to the intake manifold.

(B)

(C) (A)

FU-04972

FU-04960

7) Install the bolts which secure fuel delivery pipe to the intake manifold, and connect the pressure regulator vacuum hose to the intake manifold.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

5) Install the fuel injector.

FU-04971

8) Install PCV pipe (B) and engine harness (C) to the intake manifold, and install the brake booster vacuum hose to the clip (A).

FU-04747

6) Install the bolts which secure fuel pipe to the intake manifold.

FU(H4DOTC)-29

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) (A)

11) Connect the connector to the throttle position sensor. (C)

(B)

FU-04741

FU-04970

9) Connect the connector to the fuel injector and the tumble generator valve assembly.

12) Connect the connectors to the purge control solenoid valves 1 and 2.

FU-04740

13) Install the solenoid valve bracket assembly to the intake manifold, and connect the connector to the manifold absolute pressure sensor.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-04969

10) Install the throttle body to the intake manifold. NOTE: Use new O-rings. FU-04739

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

14) Connect the vacuum hose to the intake manifold and fuel delivery pipe.

FU-04742 FU-04738

FU(H4DOTC)-30

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

15) Install the filter assembly.

17) Install front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B) to the intake manifold protector LH, and also install clip (C) which holds the engine harness.

(C)

FU-04737

16) Install the intake manifold protector LH to the intake manifold, and install the engine ground terminal to the intake manifold protector. NOTE: Route the from front oxygen (A/F) sensor connector and rear oxygen sensor connector inside the intake manifold protector, as shown in the figure. (c)

(A)

(B)

FU-04735

18) Install the intake manifold protector RH to the intake manifold.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

(b)

(a)

FU-04753

FU-04967

E: INSPECTION

(a) Intake manifold protector (b) Front oxygen (A/F) sensor connector (c) Rear oxygen sensor connector

1) Check that the intake manifold and fuel pipe have no deformation, cracks and other damages. 2) Check that the hose has no cracks, damage or loose part.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-04968

FU(H4DOTC)-31

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Engine Coolant Temperature Sensor FUEL INJECTION (FUEL SYSTEMS)

4. Engine Coolant Temperature Sensor A: REMOVAL

CAUTION: Take care not to allow water to get into the engine coolant temperature sensor connector. Completely remove any water inside.

1) Remove the collector cover. 2) Disconnect the ground cable from battery.

(A)

(B)

IG-02107

(C)

3) Remove the generator. 4) Drain engine coolant. 5) Disconnect the connector from the engine coolant temperature sensor, and remove the engine coolant temperature sensor.

FU-04053

(A) Thermometer (B) Engine coolant temperature sensor (C) Hexagonal part height: To approx.1/3

3) Raise water temperature gradually, measure the resistance between the engine coolant temperature sensor terminals when the temperature is 20°C (68°F) and 80°C (176°F). FU-04973

B: INSTALLATION

NOTE: Agitate the water for even temperature distribution.

Install in the reverse order of removal. NOTE: Use a new gasket.

2 1

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

C: INSPECTION 1) Check that the engine coolant temperature sensor has no deformation, cracks or other damages. 2) Immerse the engine coolant temperature sensor and a thermometer in water.

EC-02428

Water temperature 20°C (68°F) 80°C (176°F)

FU(H4DOTC)-32

Terminal No.

Standard

1 and 2

2.45±0.2 kΩ 0.318±0.013 kΩ

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Crankshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

5. Crankshaft Position Sensor

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Remove the collector cover. 2) Disconnect the ground cable from battery.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-04974

IG-02107

3) Remove the bolt which secures crankshaft position sensor to oil pump.

C: INSPECTION 1. CRANKSHAFT POSITION SENSOR (METHOD WITH CIRCUIT TESTER) 1) Measure the resistance between crankshaft position sensor terminals.

2 1 FU-04974

4) Remove the crankshaft position sensor, and disconnect the connector from the crankshaft position sensor.

EC-02428

Terminal No. 1 and 2

Standard 2.04±0.204 kΩ

2. CRANKSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE) 1) Prepare an oscilloscope. 2) Remove the glove box lid assembly. FU-04975

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Crankshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

3) Connect the probe to ECM connector.

FU-04956 (A)

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26

FU-04758

(A) To ECM connector Terminal No. 17 25

Probe + –

4) Start the engine and let it idle. 5) Check that the pattern is the same as the waveform and voltage shown below. 10ms 5V

0

(A)

FU-04057

(A) One crankshaft rotation

6) After inspection, install the related parts in the reverse order of removal.

3. OTHER INSPECTIONS Check that the crankshaft position sensor has no deformation, cracks or other damages.

FU(H4DOTC)-34

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Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

6. Camshaft Position Sensor

3) Remove the camshaft position sensor LH.

A: REMOVAL 1. INTAKE SIDE • Camshaft position sensor RH 1) Disconnect the ground cable from battery.

FU-03520

2. EXHAUST SIDE 1) Disconnect the ground cable from battery.

IG-02107

2) Disconnect the connector from the camshaft position sensor RH, and remove the camshaft position sensor RH.

IG-02107

FU-04759

2) Lift up the vehicle. 3) Remove the under cover. 4) Disconnect the connector from the camshaft position sensor, and remove the camshaft position sensor. • RH side

• Camshaft position sensor LH 1) Disconnect the ground cable from battery.

FU-04760

• LH side IG-02107

2) Remove the intake manifold.

FU-04761

FU(H4DOTC)-35

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Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION

• Exhaust camshaft position sensor (A)

1. INTAKE SIDE

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26

Install in the reverse order of removal.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

2. EXHAUST SIDE Install in the reverse order of removal.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-04762

C: INSPECTION

(A) To ECM connector

1. CAMSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE) 1) Prepare an oscilloscope. 2) Remove the glove box lid assembly. 3) Connect the probe to ECM connector.

Camshaft position sensor RH Intake LH

Terminal No.

Probe

24 16

+ +

23 29 30

+ + –

RH LH

Exhaust RH and LH

4) Start the engine and let it idle. 5) Check that the pattern is the same as the waveform and voltage shown below. (B) 0 10ms

(A)

5V

(C) 0 FU-04956

• Intake camshaft position sensor

(D) 0

(A)

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26

FU-04757

(A) To ECM connector

(E) 0 FU-04763

(A) (B) (C) (D) (E)

One camshaft rotation Intake camshaft position sensor RH Intake camshaft position sensor LH Exhaust camshaft position sensor RH Exhaust camshaft position sensor LH

6) After inspection, install the related parts in the reverse order of removal.

2. OTHER INSPECTIONS Check that the camshaft position sensor has no deformation, cracks or other damages.

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Knock Sensor FUEL INJECTION (FUEL SYSTEMS)

7. Knock Sensor

B: INSTALLATION

A: REMOVAL

1) Install the knock sensor to the cylinder block.

1) Remove the collector cover. 2) Disconnect the ground cable from battery.

NOTE: The portion of the knock sensor cord that is pulled out must be positioned at a 60° angle relative to the engine rear.

Tightening torque: 24 N·m (2.4 kgf-m, 17.7 ft-lb) (A)

IG-02107

3) Remove the intercooler. 4) Disconnect the connector from the knock sensor.

60 FU-04883

(A) Front side of vehicle

2) Connect the connector to the knock sensor.

FU-04764

5) Remove the knock sensor from cylinder block. FU-04764

3) Install the intercooler. 4) Connect the ground cable to battery.

FU-04882

IG-02107

5) Install the collector cover.

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Knock Sensor FUEL INJECTION (FUEL SYSTEMS)

C: INSPECTION 1) Check that the knock sensor has no deformation, cracks or other damages. 2) Measure the resistance between knock sensor terminals.

2 1

EC-02426

Terminal No. 1 and 2

Standard 560±28 kΩ

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Throttle Position Sensor FUEL INJECTION (FUEL SYSTEMS)

8. Throttle Position Sensor A: SPECIFICATION Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to “Throttle Body” for removal and installation procedure.

FU(H4DOTC)-39

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Mass Air Flow and Intake Air Temperature Sensor FUEL INJECTION (FUEL SYSTEMS)

9. Mass Air Flow and Intake Air Temperature Sensor

2) Check that the voltage changes when air is blown to the mass air flow sensor unit from arrow direction.

A: REMOVAL 1) Disconnect the ground cable from battery.

FU-04063

IG-02107

2) Disconnect the connector from the mass air flow and intake air temperature sensor, and remove the mass air flow and intake air temperature sensor.

2. CHECK INTAKE AIR TEMPERATURE SENSOR UNIT Measure the resistance between intake air temperature sensor terminals.

5 4 3 2 1

FU-04064 FU-04765

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 1 N·m (0.1 kgf-m, 0.7 ft-lb)

Temperature –20°C (–4°F) 20°C (68°F) 60°C (140°F)

Terminal No. 1 and 2

Standard 16.0±2.4 kΩ 2.45±0.24 kΩ 0.580±0.087 kΩ

3. OTHER INSPECTIONS

C: INSPECTION 1. CHECK MASS AIR FLOW SENSOR UNIT 1) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, circuit tester positive terminal to terminal No. 5 and the circuit tester negative terminal to terminal No. 4.

1) Check that the mass air flow and intake air temperature sensor has no deformation, cracks or other damages. 2) Check that the mass air flow and intake air temperature sensor has no dirt.

5 4 3 2 1

V FU-04062

FU(H4DOTC)-40

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Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS)

10.Manifold Absolute Pressure Sensor A: REMOVAL

• Using circuit tester, check the voltage of a single dry-cell battery is 1.6 V or more. And also check the voltage of three batteries in series is between 4.8 V and 5.2 V.

1) Remove the collector cover. 2) Disconnect the ground cable from battery.

3 2 1

V

IG-02107

3) Disconnect the connector from manifold absolute pressure sensor (A), and remove the filter assembly (B) from intake manifold. 4) Remove the manifold absolute pressure sensor from the solenoid valve bracket.

1.5V

1.5V

1.5V

4.8 5.2V (A) FU-04486

(B)

3) Check the voltage at a normal atmospheric pressure.

FU-04976

NOTE: The atmospheric pressure at higher altitude is lower than normal. Therefore, the voltage is lower than the standard value. Terminal No.

B: INSTALLATION

Standard Approx. 2.2 V (when 25°C (77°F))

2 (+) and 1 (–)

Install in the reverse order of removal.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

4) Connect the Mighty Vac to the pressure port (A) of manifold absolute pressure sensor.

C: INSPECTION 1) Check that the manifold absolute pressure sensor has no deformation, cracks or other damages. 2) Connect dry-cell battery positive terminal to terminal No. 3 and dry-cell battery ground terminal to terminal No. 1, circuit tester positive terminal to terminal No. 2 and the circuit tester negative terminal to terminal No. 1. NOTE: • Use new dry-cell batteries.

(A) FU-04487

5) Check the voltage when generating vacuum and positive pressure using Mighty Vac.

FU(H4DOTC)-41

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Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS)

CAUTION: Do not apply vacuum of less than –88 — 200 kPa (–0.9 — 2.04 kgf/cm2, –12.8 — 29.0 psi). Doing so may damage the manifold absolute pressure sensor. NOTE: When vacuum occurs at the pressure port of manifold absolute pressure sensor, the voltage will drop from the value as in step 3). When positive pressure occurs, on the other hand, the voltage will rise. Pressure –88 kPa (–0.9 kgf/cm2, –12.8 psi) 152 kPa (1.55 kgf/cm2, 22.0 psi)

Terminal No.

Standard

2 (+) and 1 (–)

Approx. 1.0 V (when 25°C (77°F)) Approx. 4.5 V (when 25°C (77°F))

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Fuel Injector FUEL INJECTION (FUEL SYSTEMS)

11.Fuel Injector

8) Remove the bolt which secures the fuel pipe to the intake manifold.

A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. 2) Remove the collector cover. 3) Disconnect the ground cable from battery.

FU-04978

9) Remove the fuel injector.

IG-02107

4) Open the fuel filler lid and remove the fuel filler cap. 5) Remove the intake manifold. 6) Remove the intake manifold protector RH from intake manifold.

FU-04770

2. LH SIDE 1) Release the fuel pressure. 2) Remove the collector cover. 3) Disconnect the ground cable from battery.

FU-04967

7) Disconnect the connector from the fuel injector and tumble generator valve assembly. IG-02107

4) Open the fuel filler lid and remove the fuel filler cap. 5) Remove the intake manifold.

FU-04977

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Fuel Injector FUEL INJECTION (FUEL SYSTEMS)

6) Disconnect front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B) from the intake manifold protector LH, and also remove clip (C) which holds the engine harness.

10) Remove the fuel injector.

(C)

FU-04772

B: INSTALLATION (A)

(B)

FU-04735

7) Remove the engine ground terminal from the intake manifold protector LH, and remove the intake manifold protector LH from the intake manifold.

1. RH SIDE Install in the reverse order of removal. NOTE: Use new O-rings and seal rings.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-04968

8) Disconnect the connector from fuel injector. FU-04978

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-04979

9) Remove the bolt which secures the fuel delivery pipe to the intake manifold. FU-04967

FU-04980

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Fuel Injector FUEL INJECTION (FUEL SYSTEMS)

2. LH SIDE Install in the reverse order of removal. NOTE: Use new O-rings and seal rings.

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

T2

T1

FU-04981

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-04968

C: INSPECTION 1) Check that the fuel injector has no deformation, cracks or other damages. 2) Measure the resistance between fuel injector terminals.

2 1

EC-02428

Terminal No.

Standard

1 and 2

Approx. 12.0 Ω (when 20°C (68°F))

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Tumble Generator Valve Assembly FUEL INJECTION (FUEL SYSTEMS)

12.Tumble Generator Valve Assembly

8) Remove the tumble generator valve assembly from the intake manifold.

A: REMOVAL 1) Release the fuel pressure. 2) Remove the collector cover. 3) Disconnect the ground cable from battery.

IG-02107

4) Open the fuel filler lid and remove the fuel filler cap. 5) Remove the intake manifold. 6) Disconnect the connector from the tumble generator valve assembly.

FU-04751

B: INSTALLATION Install in the reverse order of removal. NOTE: Use a new gasket.

Tightening torque: 8.3 N·m (0.8 kgf-m, 6.1 ft-lb)

FU-03093

7) Remove the fuel injector.

to

FU-04751

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Tumble Generator Valve Assembly FUEL INJECTION (FUEL SYSTEMS)

C: INSPECTION 1) Check that the tumble generator valve assembly has no deformation, cracks or other damages. 2) Check tumble generator valve for contamination or clogging.

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Tumble Generator Valve Actuator FUEL INJECTION (FUEL SYSTEMS)

13.Tumble Generator Valve Actuator A: SPECIFICATION The tumble generator valve assembly cannot be disassembled. Refer to “Tumble Generator Valve Assembly” for removal and installation procedures.

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Oil Flow Control Solenoid Valve FUEL INJECTION (FUEL SYSTEMS)

14.Oil Flow Control Solenoid Valve

6) Disconnect the connector from the oil flow control solenoid valve, and remove the oil flow control solenoid valve from the cylinder head.

A: REMOVAL 1. INTAKE SIDE Oil flow control solenoid valve is a unit with front camshaft cap. Refer to “Camshaft” for the removal procedure.

2. EXHAUST SIDE 1) Disconnect the ground cable from battery.

FU-04775

B: INSTALLATION 1. INTAKE SIDE Refer to “Camshaft” for installation procedure.

2. EXHAUST SIDE Install in the reverse order of removal. IG-02107

2) Lift up the vehicle. 3) Remove the under cover. 4) Remove the center exhaust pipe. (LH side only)

5) Remove ground cable (A) from the engine harness cover, and remove the engine harness cover from the engine. (LH side only)

NOTE: Use a new gasket.

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb)

FU-04775

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 7 N·m (0.7 kgf-m, 5.2 ft-lb)

(A)

FU-04774

(A) T2 T1

FU(H4DOTC)-49

T1

FU-04862

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Oil Flow Control Solenoid Valve FUEL INJECTION (FUEL SYSTEMS)

C: DISASSEMBLY

Tightening torque: 9 N·m (0.9 kgf-m, 6.6 ft-lb)

1. INTAKE SIDE 1) Remove the two bolts which secure the oil return cover, and remove the oil return cover and gasket. 2) Remove the bolt which secures the oil flow control solenoid valve and remove the oil flow control solenoid valve.

(D) (C)

(B)

(A)

(D) (C)

(B)

FU-04776

(A)

(A) (B) (C) (D)

Oil flow control solenoid valve Oil return cover Gasket Front camshaft cap

FU-04776

(A) (B) (C) (D)

2. EXHAUST SIDE

Oil flow control solenoid valve Oil return cover Gasket Front camshaft cap

The oil flow control solenoid valve on exhaust side cannot be disassembled.

E: INSPECTION

2. EXHAUST SIDE The oil flow control solenoid valve on exhaust side cannot be disassembled.

1) Check that the oil flow control solenoid valve has no deformation, cracks or other damages. 2) Measure the resistance between the oil flow control solenoid valve terminals.

D: ASSEMBLY 1. INTAKE SIDE

2 1

1) Install the oil flow control solenoid valve.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 2) Apply liquid gasket to the two bolts which secure the oil return cover. Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent 3) Install the oil return cover and gasket.

EC-02428

Terminal No.

Standard

1 and 2

7.4±0.5 Ω (when 20°C (68°F))

NOTE: Use a new gasket.

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Wastegate Control Solenoid Valve FUEL INJECTION (FUEL SYSTEMS)

15.Wastegate Control Solenoid Valve

B: INSTALLATION

A: REMOVAL

NOTE: Use new O-rings.

1) Disconnect the ground cable from battery.

Install in the reverse order of removal.

Tightening torque: 1 N·m (0.1 kgf-m, 0.7 ft-lb)

C: INSPECTION 1) Check that the wastegate control solenoid valve has no deformation, cracks or other damages. 2) Check the resistance between the wastegate control solenoid valve terminals.

IG-02107

2 1

2) Remove the radiator sub fan motor assembly.

3) Remove the screws which hold the wastegate control solenoid valve to the intake duct.

EC-02426

Terminal No. 1 and 2

Standard 24±3 Ω (when 20°C (68°F))

3) Check that air does not come out from (B) when air is blown into (A). FU-04777

4) Lift up the vehicle. 5) Remove the under cover. 6) Disconnect the connector and air control hose from the wastegate control solenoid valve, and remove the wastegate control solenoid valve from the intake duct.

FU-04778

FU(H4DOTC)-51

(A)

(B) FU-04779

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Wastegate Control Solenoid Valve FUEL INJECTION (FUEL SYSTEMS)

4) With terminal No. 1 connected to the battery positive terminal and terminal No. 2 to the battery ground terminal, check that air comes out from (B) when air is blown into (A).

2 1

(A)

(B) FU-04780

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Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS)

16.Front Oxygen (A/F) Sensor

B: INSTALLATION

A: REMOVAL

CAUTION: If lubricant is spilt over the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier.

1) Disconnect the ground cable from battery.

CAUTION: Never apply anti-seize compound to the protector of front oxygen (A/F) sensor. IG-02107

2) Remove the radiator main fan motor assembly.

3) Disconnect the connector from the front oxygen (A/F) sensor, and remove the clip (A) holding the front oxygen (A/F) sensor harness.

Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the front oxygen (A/F) sensor. Tightening torque: 30 N·m (3.1 kgf-m, 22.1 ft-lb)

(A) FU-04782 FU-04982

4) Apply spray-type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. 5) Remove the front oxygen (A/F) sensor by using a sensor socket.

3) Connect the front oxygen (A/F) sensor connector, and secure the front oxygen (A/F) sensor harness by using the clip (A).

CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.

(A)

FU-04982

4) Install the radiator main fan motor assembly.

FU-04782

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Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS)

5) Connect the ground cable to battery.

IG-02107

C: INSPECTION 1) Check that the front oxygen (A/F) sensor has no deformation, cracks or other damages. 2) Measure the resistance between front oxygen (A/F) sensor terminals.

1 2 3 4

FU-04072

Terminal No.

Standard

1 and 2

2.4±0.24 Ω (when 20°C (68°F))

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Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS)

17.Rear Oxygen Sensor

B: INSTALLATION

A: REMOVAL

CAUTION: If lubricant is spilt over the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing rear oxygen sensor, apply the anti-seize compound only to the threaded portion of rear oxygen sensor to make the next removal easier.

1) Disconnect the ground cable from battery.

CAUTION: Never apply anti-seize compound to the protector of rear oxygen sensor. IG-02107

2) Remove the radiator main fan motor assembly.

3) Disconnect the connector from the rear oxygen sensor, and remove the clip (A) holding the rear oxygen sensor harness.

Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the rear oxygen sensor. Tightening torque: 30 N·m (3.1 kgf-m, 22.1 ft-lb)

(A) FU-04784 FU-04983

4) Apply spray-type lubricant to the threaded portion of rear oxygen sensor, and leave it for one minute or more. 5) Remove the rear oxygen (A/F) sensor by using a sensor socket.

3) Connect the connector to the rear oxygen sensor, and hold the rear oxygen sensor harness with clip (A).

CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.

(A)

FU-04983

4) Install the radiator main fan motor assembly.

FU-04784

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Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS)

5) Connect the ground cable to battery.

IG-02107

C: INSPECTION 1) Check that the rear oxygen sensor has no deformation, cracks or other damages. 2) Measure the resistance between rear oxygen sensor terminals.

1 2 3 4

FU-04072

Terminal No.

Standard

1 and 2

5.6+0.8 –0.6 Ω (when 20°C (68°F))

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Engine Control Module (ECM) FUEL INJECTION (FUEL SYSTEMS)

18.Engine Control Module (ECM)

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Disconnect the ground cable from battery.

IG-02107

2) Remove the glove box lid assembly. 3) Remove the connectors from ECM.

CAUTION: • When the ECM of model with immobilizer has been replaced, be sure to perform the registration of immobilizer system. (Refer to “PC application help for Subaru Select Monitor”.) • If replacing ECM or the bracket, replace both parts with new parts at a time. • After installing the bracket to ECM, do not separate the bracket. • If the bracket has been installed to ECM in the wrong direction, replace both parts to new parts. NOTE: When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

C: INSPECTION Check that the ECM has no deformation, cracks or other damages.

FU-04984

4) Remove the ECM from vehicle.

FU-04985

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Main Relay FUEL INJECTION (FUEL SYSTEMS)

19.Main Relay

C: INSPECTION

A: REMOVAL

1) Check that the main relay has no deformation, cracks or other damages. 2) Measure the resistance between main relay terminals.

1) Disconnect the ground cable from battery.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

IG-02107

2) Remove the glove box lid assembly. 3) Remove the main relay from the relay holder.

1 2 3 4

FU-04076 FU-04986

B: INSTALLATION

Terminal No. 1 and 2

Standard 1 MΩ or more

3 and 4

130.4 — 230.8 Ω (When 20°C (68°F))

Install in the reverse order of removal.

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Main Relay FUEL INJECTION (FUEL SYSTEMS)

3) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, and measure the resistance between the main relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2 3 4

FU-04077

Terminal No. 1 and 2

Standard Less than 1 Ω

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Fuel Pump Relay FUEL INJECTION (FUEL SYSTEMS)

20.Fuel Pump Relay

C: INSPECTION

A: REMOVAL

1) Check that the fuel pump relay has no deformation, cracks or other damages. 2) Measure the resistance between fuel pump relay terminals.

1) Disconnect the ground cable from battery.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

IG-02107

2) Remove the glove box lid assembly. 3) Remove the fuel pump relay from the relay holder.

1 2 3 4

FU-04076

FU-04987

Terminal No. 1 and 2

Standard 1 MΩ or more

3 and 4

93.8 — 136.4 Ω (When 20°C (68°F))

B: INSTALLATION Install in the reverse order of removal.

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Fuel Pump Relay FUEL INJECTION (FUEL SYSTEMS)

3) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, and measure the resistance between the fuel pump relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2 3 4

FU-04077

Terminal No. 1 and 2

Standard Less than 1 Ω

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Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEMS)

21.Electronic Throttle Control Relay A: REMOVAL 1) Disconnect the ground cable from battery.

C: INSPECTION 1) Check that the electronic throttle control relay has no deformation, cracks or other damages. 2) Measure the resistance between electronic throttle control relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

IG-02107

2) Remove the glove box lid assembly. 3) Remove the electronic throttle control relay from the relay holder.

1 2 3 4

FU-04076

Terminal No. 1 and 2

Standard 1 MΩ or more

3 and 4

93.8 — 136.4 Ω (When 20°C (68°F))

FU-04988

B: INSTALLATION Install in the reverse order of removal.

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Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEMS)

3) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, and measure the resistance between the electronic throttle control relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2 3 4

FU-04077

Terminal No. 1 and 2

Standard Less than 1 Ω

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Fuel Pump Control Unit FUEL INJECTION (FUEL SYSTEMS)

22.Fuel Pump Control Unit A: REMOVAL 1) Disconnect the ground cable from battery.

IG-02107

2) Remove the trunk trim panel assembly-side RH.

3) Remove the fuel pump control unit.

FU-04793

4) Disconnect the connector from fuel pump control unit.

FU-04795

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

C: INSPECTION Check that the fuel pump control unit has no deformation, cracks or other damages.

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Fuel FUEL INJECTION (FUEL SYSTEMS)

23.Fuel

• Catch the fuel from hoses using a container or cloth.

A: PROCEDURE 1. RELEASING OF FUEL PRESSURE

(A)

ST

WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Remove the fuse of fuel pump from main fuse box.

(B)

(C)

ME-04382

(A) Fuel delivery hose (B) Fuel return hose (C) Evaporation hose

FU-04800

2) Start the engine and run it until it stalls. 3) After the engine stalls, crank it for five more seconds. 4) Turn the ignition switch to OFF. 5) Install the fuse of fuel pump to the main fuse box.

3) Connect ST to the fuel delivery hose. ST 18471AA000 FUEL PIPE ADAPTER 4) Connect the gasoline proof hose to ST and put the end of the hose in the container. 5) Drive the fuel pump and drain the fuel using Subaru Select Monitor. (Refer to “PC application help for Subaru Select Monitor”.) CAUTION: Be careful not to spill fuel. 6) Install the related parts in the reverse order after draining the fuel.

2. DRAINING FUEL (WITH SUBARU SELECT MONITOR)

3. DRAINING FUEL (THROUGH THE FUEL FILLER HOSE)

WARNING: Place “NO OPEN FLAMES” signs near the working area.

WARNING: Place “NO OPEN FLAMES” signs near the working area.

CAUTION: Be careful not to spill fuel.

CAUTION: • Be careful not to spill fuel. • Fuel may remain in the fuel filler pipe. Draining the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose (ø10 or less) before the operation. 1) Lift up the vehicle. 2) Remove the rear exhaust pipe and muffler. 3) Remove the rear sub frame. 4) Open the fuel filler lid and remove the fuel filler cap. 5) Drain the fuel from the fuel filler pipe through the filler opening using the gasoline proof pump and the gasoline proof hose (ø10 or less). 6) Disconnect the fuel filler hose from the fuel filler pipe assembly.

NOTE: • If the fuel pump cannot be driven, refer to the procedures for draining from the fuel filler hose.

• Be careful not to let the battery run-out. 1) Release the fuel pressure. 2) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION: • Be careful not to spill fuel.

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Fuel FUEL INJECTION (FUEL SYSTEMS)

CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth.

FU-04989

7) Set the container under the vehicle and insert the gasoline proof hose (ø10 or less) into the fuel filler hose to drain the fuel. CAUTION: Be careful not to spill fuel. 8) Install the related parts in the reverse order after draining the fuel.

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb)

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

24.Fuel Tank

(3) Push the grommet (D) down and remove the service hole cover.

A: REMOVAL

(C)

WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery.

(D)

(B) (C) (A)

FU-04991

7) Remove the service hole cover of fuel sub level sensor.

FU-04992 IG-02107

4) Remove the rear seat cushion. 5) Remove the clips (A) and seat cushion hooks (B), and turn over the floor mat (C).

8) Disconnect the quick connector of fuel delivery tube (A) and fuel return tube (B). (A)

(B)

(C)

(B)

(A)

(A)

(B) FU-04990

6) Remove the service hole cover of fuel pump. (1) Disconnect the fuel cord connector (A), and remove the clip (B). (2) Remove the screw (C).

FU-04993

9) Remove the rear wheels. 10) Lift up the vehicle. 11) Remove the rear ABS wheel speed sensor from the rear housing.

FU-04994

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

12) Remove the rear ABS wheel speed sensor harness bracket from the upper arm.

16) Remove the rear exhaust pipe and muffler. 17) Remove the propeller shaft. 18) Remove the clip (A) securing the fuel tank protector and heat shield cover. 19) Remove the bolts (B) and nuts (C) securing the fuel tank protector, and remove the fuel tank protector. (B)

FU-04087

13) Remove the rear brake hose bracket from rear housing.

(B)

(B) (C)

(C) (A)

FU-04997

20) Remove the bolts and nuts securing the heat shield cover and remove the heat shield cover. FU-04995

14) Remove the rear disc brake assembly and tie it to the body side of the vehicle.

FU-04998

21) Remove the rear suspension assembly. WARNING: A helper is required to perform this work. (1) Support the rear differential with the transmission jack. (2) Remove the bolt and nut which secure rear shock absorber to rear suspension arm.

FU-04996

15) Remove the parking brake cable from parking brake assembly.

FU(H4DOTC)-68

FU-03359

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

(3) Remove the bolts which secure the rear suspension assembly to the body.

NOTE: Disconnect the quick connector as shown in the figure. 1 2

FU-04999 1

(4) Remove the rear suspension assembly. 22) Disconnect the PCV drain hose (A) and PCV outlet hose (B) from the pressure control solenoid valve.

FU-05002

(A) (B) FU-05003

FU-05000

25) Disconnect the fuel filler hose (A), PCV inlet hose (B) and circulate hose (C) from the fuel filler pipe assembly.

23) Disconnect the air vent hose from the fuel tank. (C)

(B)

(A)

FU-05049 FU-05001

24) Disconnect the quick connector of the circulate tube from evaporation pipe.

26) Support the fuel tank with a transmission jack, remove the bolts from the fuel tank band, and remove the fuel tank from the vehicle. WARNING: • A helper is required to perform this work.

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

• Fuel may remain in the fuel tank. This will cause the left and right sides to be unbalanced. Be careful not to drop the fuel tank when removing.

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb) (C)

(B)

(A)

FU-05049 FU-05004

(1)

(2)

(3)

(4)

B: INSTALLATION 1) Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band. WARNING: A helper is required to perform this work.

L/2 L

FU-04500

(1) (2) (3) (4)

Hose Clamp or clip Spool or stopper Pipe

3) Connect the quick connector of the circulate tube to the evaporation pipe as shown in the figure. FU-05004

2) Securely insert the fuel filler hose (A), PCV inlet hose (B) and circulate hose (C) to the spool or stopper, then attach the clamp or clip as shown in the figure.

CAUTION: • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

• Make sure that the quick connector is securely connected.

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb) 1

2

4

3 FU-05036

FU-05005

7) Install the rear suspension assembly. WARNING: A helper is required to perform this work. (1) Support the rear differential with the transmission jack. (2) While supporting the rear suspension assembly, install the rear suspension assembly to the body. FU-05003

4) Connect the air vent hose to fuel tank.

Tightening torque: T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb) T2: 200 N·m (20.4 kgf-m, 147.5 ft-lb)

T2

T2

T1

T1

FU-05001

5) Connect the PCV drain hose (A) and PCV outlet hose (B) to the pressure control solenoid valve.

FU-05006

(3) Install the rear shock absorber to the rear suspension arm. NOTE: Use a new self-locking nut.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb)

(A) (B)

FU-05000

6) Tighten the bolts of the fuel tank band in the order shown in the figure. FU-03359

8) Install the heat shield cover.

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

FU-04998

9) Install the bolts (B) and nuts (C) securing the fuel tank protector and install the clip (A) securing the fuel tank protector and heat shield cover.

Tightening torque: Nut (C): 9 N·m (0.9 kgf-m, 6.6 ft-lb) Bolt (B): 18 N·m (1.8 kgf-m, 13.3 ft-lb)

FU-04995

16) Install the rear ABS wheel speed sensor harness bracket to the upper arm.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(B)

(B)

(B) (C)

(C) (A)

FU-04087 FU-04997

10) Install the propeller shaft. 11) Install the rear exhaust pipe and muffler. 12) Lower the vehicle. 13) Connect the parking brake cable to the parking brake assembly. 14) Install the rear disc brake assembly.

Tightening torque: 66 N·m (6.7 kgf-m, 48.7 ft-lb)

17) Install the rear ABS wheel speed sensor to the rear housing.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

FU-04994

18) Install the rear wheels.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb) 19) Connect the quick connector of fuel delivery tube (A) and fuel return tube (B).

FU-04546

15) Install the rear brake hose bracket to the rear housing.

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

NOTE: When connecting, be careful not to reverse the delivery side and return side.

22) Set the floor mat (C), and install clips (A) and seat cushion hooks (B).

(A)

(C) (B) (B) FU-04993

20) Install the service hole cover of fuel sub level sensor.

(A)

(C)

IG-02107

25) Inspect the wheel alignment and adjust if necessary.

C: INSPECTION 1) Check that the fuel tank and fuel pipe have no deformation, cracks and other damages. 2) Check that the fuel hose has no cracks, damage or loose part.

(D)

(B) (C) (A)

(A) (B) (C) (D)

(B) FU-04990

23) Install the rear seat cushion. 24) Connect the ground cable to battery.

FU-04992

21) Install the service hole cover of the fuel pump, and install the connector and clip.

(A)

FU-04991

Connector Clip Screw Grommet

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Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS)

25.Fuel Filler Pipe

10) Disconnect the fuel filler hose (A), PCV inlet hose (B) and circulate hose (C) from the fuel filler pipe assembly.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery.

(C)

(B)

(A)

FU-05049

11) Disconnect the evaporation hose (A) from fuel filler pipe assembly and remove the bolts and nuts securing the fuel filler pipe assembly to the vehicle body.

(A)

IG-02107

4) Open the fuel filler lid, and remove the filler cap. 5) Turn the fuel filler pipe protector in the direction of the arrow to unlock and remove it.

FU-04044

6) Remove the rear wheel RH. 7) Lift up the vehicle. 8) Remove the rear mud guard RH. 9) Remove the rear sub frame.

FU-05007

12) Remove the fuel filler pipe assembly from the underside of the vehicle.

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Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 1) Open the fuel filler lid. 2) Insert the fuel filler pipe assembly into the rubber saucer from inside of the rear fender. 3) Install the fuel filler pipe assembly to the vehicle body and connect the evaporation hose (A) to the fuel filler pipe assembly.

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb) (C)

(B)

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(A)

FU-05049 (A) (1)

(2)

(3)

(4)

L/2 L

FU-04500

(1) (2) (3) (4)

FU-05007

4) Align the cutout on the fuel filler pipe protector and the protrusion of the neck holder and insert them all the way, and then turn the fuel filler pipe protector in the direction of the arrow until it is locked.

Hose Clamp or clip Spool or stopper Pipe

6) Install the rear sub frame. 7) Install the rear mud guard RH. 8) Lower the vehicle. 9) Install the rear wheel RH.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb) 10) Connect the ground cable to battery.

FU-04104

5) Securely insert the fuel filler hose (A), PCV inlet hose (B) and circulate hose (C) to the spool or stopper, then attach the clamp or clip as shown in the figure.

IG-02107

11) Inspect the wheel alignment and adjust if necessary.

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Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS)

C: DISASSEMBLY

D: ASSEMBLY

1) Remove the shut valve from the fuel filler pipe.

2) Remove the evaporation pipe from the fuel filler pipe.

1) Temporarily tighten the bolts securing the fuel filler pipe bracket to the fuel filler pipe.

FU-05009

2) Install the evaporation pipe to the fuel filler pipe. FU-05008

3) Remove the fuel filler pipe bracket from the fuel filler pipe.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

FU-05008 FU-05009

3) Tighten the bolts securing the fuel filler pipe bracket to the fuel filler pipe.

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Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 7.35 N·m (0.7 kgf-m, 5.4 ft-lb)

FU-05010

4) Install the shut valve to the fuel filler pipe.

E: INSPECTION 1) Check that the fuel filler pipe and evaporation pipe do not have deformation, cracks or other damages. 2) Check that the hose has no cracks, damage or loose part.

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Fuel Pump FUEL INJECTION (FUEL SYSTEMS)

26.Fuel Pump

(3) Push the grommet (D) down and remove the service hole cover.

A: REMOVAL

(C)

WARNING: Place “NO OPEN FLAMES” signs near the working area.

(D)

CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: Fuel pump assembly consists of fuel pump, fuel filter, fuel chamber and fuel level sensor. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery.

(B) (C) (A)

FU-04991

7) Disconnect the connector (A) from fuel pump, and remove the clip (B) securing the harness. 8) Disconnect the quick connector of fuel delivery tube (C), fuel return tube (D) and fuel sub delivery tube (E). 9) Remove the rubber cap (F) from nut. (D) (E)

(F)

(C) (A)

(B)

IG-02107

FU-05011

10) Remove the nuts securing the fuel pump upper plate to the fuel tank and remove the fuel pump upper plate.

4) Remove the rear seat cushion. 5) Remove the clips (A) and seat cushion hooks (B), and turn over the floor mat (C).

FU-04534

(C)

(B)

(A)

11) Remove the fuel pump assembly from the fuel tank. (A)

(B) FU-04990

6) Remove the service hole cover. (1) Disconnect the fuel cord connector (A), and remove the clip (B). (2) Remove the screw (C).

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Fuel Pump FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION

C: INSPECTION

Install in the reverse order of removal while being careful of the following. • Make sure the sealing portion is free from fuel or foreign matter before installation. • Align protrusion (A) of the gasket to the position shown in the figure. • Insert the protrusion (B) of gasket to the fuel pump upper plate. (3 places) • Align the protrusion (C) of fuel pump assembly with the cutout on the fuel pump upper plate. • Tighten the nuts to the specified torque in the order as shown in the figure. • After assembly, install the rubber cap (D) to the position shown in the figure.

1) Check that the fuel pump has no deformation, cracks or other damages. 2) Connect battery positive terminal to terminal No. 5 and battery ground terminal to terminal No. 6, and inspect the fuel pump operation. WARNING: • Wipe off fuel completely. • Keep the battery as far apart from fuel pump as possible. • Do not run the fuel pump for a long time under non-load condition.

NOTE: • Use a new gasket and retainer. • Do not forget to install the rubber cap (D).

2 1 4 3 6 5

Tightening torque: 4.4 N·m (0.4 kgf-m, 3.2 ft-lb) 2

(C)

4

FU-04110 7

(B)

(B) 6

5

(D) (a)

3

8 (B)

1

(A)

FU-05012

(a) Front side of vehicle

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Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS)

27.Fuel Level Sensor

4) Press two claws (A) of the fuel level sensor, and slide the fuel level sensor in the direction of the arrow to remove the fuel level sensor.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area.

(A)

(A)

CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: The fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly. 2) Disconnect the connector from the fuel filter assembly.

FU-05015

B: INSTALLATION Install in the reverse order of removal.

C: INSPECTION 1) Check that the fuel level sensor has no damage. 2) Measure the fuel level sensor float position. NOTE: When inspecting the fuel level sensor, perform the work with the sensor installed to the fuel pump. • Model with fuel level sensor bent in 3 locations

(1) FU-05013

3) Remove the harness from the hooks (A) on the fuel chamber assembly and remove the fuel temperature sensor (B) from fuel chamber assembly.

(A)

(3)

(B)

(2) (B)

FU-05016

(1) FULL (2) EMPTY (3) Fuel tank seating surface

(A)

FU-05014

Float position FULL to Fuel tank seating surface (A) EMPTY to Fuel tank seating surface (B)

FU(H4DOTC)-80

Standard 126.4±4 mm (4.976±0.157 in) 11.0±4 mm (0.433±0.157 in)

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Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS)

• Model with fuel level sensor bent in 2 locations

• Model with fuel level sensor bent in 2 locations

(1) (A) (A) (2) (3)

(B)

(B)

FU-08404

(1) FULL (2) EMPTY (3) Fuel tank seating surface Float position FULL to Fuel tank seating surface (A) EMPTY to Fuel tank seating surface (B)

2 1 4 3 6 5 Standard

120.9±4 mm (4.759±0.157 in) 14.8±4 mm (0.583±0.157 in)

3) Measure the resistance between fuel level sensor terminals. • Model with fuel level sensor bent in 3 locations

FU-08405

Float position FULL (A) EMPTY (B)

(A)

(B)

2 1 4 3 6 5

FU-05017

FU(H4DOTC)-81

Terminal No. 1 and 4

Standard 2.0±1.0 Ω 31.9±1.0 Ω

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Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS)

28.Fuel Sub Level Sensor

6) Disconnect the connector (A) from fuel sub level sensor, and remove the clip (B) securing the fuel cord from fuel sub level sensor protector.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery.

(B) (A)

FU-05018

7) Remove the bolts (A) securing the fuel sub level sensor protector to the fuel sub level sensor upper plate, and remove the fuel sub level sensor protector. 8) Disconnect the quick connector on the fuel sub delivery tube (B). (A)

(B)

IG-02107

4) Remove the rear seat cushion. 5) Remove the service hole cover.

FU-05019

9) Remove the nuts securing the fuel sub level sensor upper plate to the fuel tank and remove the fuel sub level sensor upper plate.

FU-04992 FU-04569

10) Remove the fuel sub level sensor from the fuel tank.

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Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION

C: INSPECTION

Install in the reverse order of removal while being careful of the following. • Make sure the sealing portion is free from fuel or foreign matter before installation. • Align protrusion (A) of the gasket to the position shown in the figure. • Align protrusion (B) of the fuel sub level sensor to the cutout in the fuel sub level sensor upper plate. • After tightening the bolts to the specified torque in the order indicated in the figure, install the fuel sub level sensor protector.

1) Check that the fuel sub level sensor has no damage. 2) Measure the fuel sub level sensor float position. (A)

(1) (3)

(B)

NOTE: Use a new gasket and retainer.

(2) FU-04213

Tightening torque: 4.4 N·m (0.4 kgf-m, 3.2 ft-lb)

(1) FULL (2) EMPTY (3) Datum points

4 2

Float position

6

FULL to Datum point (A) 5

EMPTY to Datum point (B) (a)

1

(B) 3 (A)

FU-04533

Standard 6.4±3.5 mm (0.252±0.138 in) 163.3±3.5 mm (6.429±0.138 in)

3) Measure the resistance between fuel sub level sensor terminals.

(a) Front side of vehicle (A)

(B)

FU-05020

2 1

FU-04214

Float position FULL (A) EMPTY (B)

FU(H4DOTC)-83

Terminal No. 1 and 2

Standard 2.0±1.0 Ω 62.1±1.0 Ω

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Fuel Filter FUEL INJECTION (FUEL SYSTEMS)

29.Fuel Filter

5) Remove the fuel pump holder from the fuel filter assembly.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. • Be careful not to drop or apply any impact to the fuel pump during work. This may deteriorate its performance.

FU-05023

6) Remove the fuel pump from the fuel filter assembly.

NOTE: The fuel filter is built in fuel pump assembly. 1) Remove the fuel pump assembly. 2) Remove the fuel level sensor and fuel temperature sensor. 3) Disconnect the connector from the fuel filter assembly.

FU-05021

4) Disengage the claw connecting the fuel filter assembly and fuel chamber assembly, and separate fuel filter assembly and fuel chamber assembly.

FU-05022

FU(H4DOTC)-84

FU-05024

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Fuel Filter FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 1) Assemble the gasket spacer (A) and support rubber cushion (B) to the fuel pump, and install the fuel pump to the fuel filter assembly. NOTE: • Use a new gasket spacer. • Use a new support rubber cushion. • Apply gasoline to the surface of gasket spacer and support rubber cushion.

• Check that the claw connecting the fuel filter assembly and fuel chamber assembly is securely fastened.

(B)

(B)

(A) (A)

(A)

FU-03889

FU-05025

2) Install the fuel pump holder to the fuel filter assembly. FU-05022

4) Connect the fuel pump connector.

FU-03886

3) Install the pump module spring (A) to fuel filter assembly, and install the fuel chamber assembly (B). NOTE: • Use a new fuel chamber assembly.

FU-05021

5) Install the fuel level sensor and fuel temperature sensor. 6) Inspect the fuel level sensor. 7) Install the fuel pump assembly.

FU(H4DOTC)-85

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Fuel Damper FUEL INJECTION (FUEL SYSTEMS)

30.Fuel Damper A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. 1) Release the fuel pressure. 2) Disconnect the fuel delivery hose (A) and fuel return hose (B) from the fuel damper, and remove the fuel damper. (A)

(A)

(B)

(B)

FU-05026

B: INSTALLATION Install in the reverse order of removal. NOTE: If fuel hoses or clamps are damaged, replace them with new parts.

Tightening torque: 1.25 N·m (0.1 kgf-m, 0.9 ft-lb)

C: INSPECTION 1) Check that the fuel damper has no deformation, cracks or other damages. 2) Check that the fuel hose has no cracks, damage or loose part.

FU(H4DOTC)-86

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Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

31.Fuel Delivery, Return and Evaporation Lines A: REMOVAL

FU-05027

WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. 3) Open the fuel filler lid and remove the fuel filler cap. 4) Remove the floor mat. 5) In the engine compartment, disconnect the fuel delivery hoses, fuel return hoses and evaporation hoses. CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth.

(1) Remove the connect check cover from the fuel delivery hose and fuel return hose.

FU-05028

ST

(2) Install the ST to the fuel pipe. 42099AE000 QUICK CONNECTOR RELEASE (3) Disconnect the quick connector of the fuel delivery hose and fuel return hose by pushing the ST in the direction of the arrow.

FU(H4DOTC)-87

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Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

(4) Remove the clip and disconnect the evaporation hose from the fuel pipe. (F) (D)

ST (E)

(B) (C)

(A)

(A)

FU-05030

(C) (B) FU-05029

(A) Fuel delivery hose (B) Fuel return hose (C) Evaporation hose

6) Remove the fuel tank. 7) Remove the rear mud guard LH. 8) Remove the purge hose (A), purge pipe (B), air vent hose (C), PCV outlet hose (D), PCV drain hose (E) and drain tube assembly (F).

9) Remove the fuel pipe assembly from vehicle. 10) Disconnect the quick connector, then disconnect the fuel delivery tube, fuel return tube and fuel sub delivery tube. (1) Push the retainer in the direction of the arrow, disconnect the quick connector from pipe. NOTE: Clean the pipe and quick connector, if they are covered with dust.

(B)

NOTE: Disconnect the quick connector as shown in the figure.

(A)

(C)

1 2

FU-00124

(A) Quick connector (B) Retainer (C) Pipe

(2) To prevent from damaging or entering foreign matter, wrap the pipes and quick connectors with plastic bag etc.

1 (a) 1 2

(b)

1

EC-02590

(a) Air vent hose (C), drain tube ASSY (F) (b) PCV outlet hose (D), PCV drain hose (E)

FU-01333

11) Remove the evaporation pipe. (1) Remove the rear mud guard RH.

FU(H4DOTC)-88

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Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION

(2) Remove the evaporation hose.

Install in the reverse order of removal while being careful of the following.

1. INSTALLATION OF EVAPORATION PIPE 1) Install the evaporation pipe to the vehicle.

FU-05031

(3) Remove the trunk side trim panel assembly - side on RH. (4) Remove the evaporation pipe protector. FU-05033

2) Install the evaporation pipe protector.

Tightening torque: T1: 1 N·m (0.1 kgf-m, 0.7 ft-lb) T2: 7.5 N·m (0.7 kgf-m, 5.4 ft-lb) T2

FU-05032

(5) Remove the evaporation pipe from the vehicle.

T1

FU-05034

3) Install the trunk side trim panel assembly - side on RH. 4) Install the evaporation hose. FU-05033

FU-05031

5) Install the rear mud guard RH.

FU(H4DOTC)-89

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Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

2. CONNECTING THE FUEL LINE QUICK CONNECTOR

• Be sure to inspect tubes and their connections for any leakage of fuel.

CAUTION: Make sure there are no damage or dust on connections. If necessary, clean seal surface of pipe.

(A) (B)

(C) (A)

FU-00126

(B)

FU-00125

(A) Quick connector (B) Retainer (C) Pipe

3. CONNECT FUEL DELIVERY HOSE AND FUEL RETURN HOSE.

(A) Seal surface (B) Pipe

Connect the fuel delivery hose and fuel return hose as shown in the figure.

1) Set the retainer to quick connector. NOTE: Use a new retainer. 2) Connect the quick connector to pipe. CAUTION: • Make sure that the quick connector is securely connected.

CAUTION: • If the connection portion has a spool or stopper, do not allow the end of the hose to bend or ride over by inserting the hose too deep. • Be sure to inspect hoses and their connections for any leakage of fuel.

Tightening torque: 1.25 N·m (0.1 kgf-m, 0.9 ft-lb) L1: 2.5±1.5 mm (0.098±0.059 in) L2: 22.5±2.5 mm (0.886±0.098 in) (3) (4) (5)

(A)

(6)

(1) (B)

(C)

L1 FU-00127 L2

(A) Quick connector (B) Retainer (C) Pipe

(2) L1

• Make sure the two retainer pawls are engaged in their mating positions in the quick connector.

(1) (2) (3) (4) (5) (6)

FU(H4DOTC)-90

FU-04503

When there is a spool or stopper When there is no spool or stopper Pipe Spool or stopper Clamp Hose

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Fuel Delivery, Return and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

4. EVAPORATION HOSE CONNECTION

C: INSPECTION

Connect the evaporation hose to the pipe with an overlap of 15 to 20 mm (0.59 to 0.79 in).

1) Check that the fuel pipe has no deformation, cracks or other damages. 2) Check that the hose and tube have no cracks, damage or loose part.

L = 17.5±2.5 mm (0.689±0.098 in) (2)

(1)

(3)

L/2 L FU-04501

(1) Hose (2) Clip (3) Pipe

5. CONNECTING THE EVAPORATION LINE QUICK CONNECTOR CAUTION: • Make sure there are no damage or dust on connections. If necessary, clean the seal surface of the pipe. • Make sure that the quick connector is securely connected. Connect the quick connector as shown in the figure.

FU-05035

FU(H4DOTC)-91

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Fuel System Trouble in General FUEL INJECTION (FUEL SYSTEMS)

32.Fuel System Trouble in General A: INSPECTION Trouble

Insufficient fuel supply to injector

Possible cause a. Fuel pump does not operate. Defective terminal contact

Inspect contact, especially ground, and tighten it securely.

Trouble in electromagnetic or electronic circuit parts

Replace the faulty parts.

b. Decline of fuel pump function

Replace the fuel pump.

c. Clogged fuel filter

Replace the fuel filter. Clean or replace the fuel tank if necessary.

d. Clogged or bent pipe, hose or tube of fuel line

Clean, correct or replace the pipe, hose or tube of the fuel line.

e. Air is mixed in fuel system.

Leakage or run-out of fuel

Gasoline smell inside of compartment Defective fuel gauge Noise

Corrective action

f. Damaged diaphragm of pressure regulator a. Loose connection in pipe, hose or tube of fuel line b. Cracks in pipe, hose or tube of fuel line c. Cracks or defective welded part of fuel tank

Check the fuel line connections, and repair or replace the defective part. Replace the pressure regulator. Check the fuel line connections, and repair or replace the defective part. Replace the pipe, hose or tube of the fuel line. Replace the fuel tank.

d. Clogged or bent pipe, hose or tube of fuel line

Clean, correct or replace the pipe, hose or tube of the fuel line.

a. Loose connection in pipe, hose or tube of fuel line b. Improper installation of rubber saucer c. Defective canister

Check the fuel line connections, and repair or replace the defective part. Correct or replace the rubber saucer. Replace the canister.

a. Defective operation of fuel level sensor Replace the fuel level sensor. b. Defective operation of combination meter Replace the combination meter. a. Big operation noise or vibration from fuel pump Replace the fuel pump.

NOTE: • When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank. Fill fuel fully to prevent the problem. • In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop to 0°C (32°F) or less throughout the winter season, use a water removing agent in the fuel system to prevent freezing fuel system and accumulating water. • When water is accumulated in fuel filter, fill the water removing agent in the fuel tank. • Before using water removing agent, follow the cautions noted on the bottle.

FU(H4DOTC)-92

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EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(H4DOTC) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Page General Description ...................................................................................2 Front Catalytic Converter ...........................................................................3 Rear Catalytic Converter ............................................................................4 Canister ......................................................................................................5 Purge Control Solenoid Valve ....................................................................9 Fuel Level Sensor ....................................................................................14 Fuel Temperature Sensor ........................................................................15 Fuel Sub Level Sensor .............................................................................16 Fuel Tank Pressure Sensor .....................................................................17 Pressure Control Solenoid Valve .............................................................19 Drain Filter ................................................................................................20 Shut Valve ................................................................................................21 Drain Valve ...............................................................................................22 PCV Hose Assembly ................................................................................23 PCV Valve ................................................................................................24

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General Description EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

1. General Description A: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.

B: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 18353AA000

DESCRIPTION CLAMP PLIERS

REMARKS • Used for removing and installing the PCV hose. • This tool is made by the French company CAILLAU. (code) 54.0.000.205 To make it easier to obtain, it has been provided with a tool number.

ST18353AA000

2. GENERAL TOOL TOOL NAME Circuit tester Mighty Vac

REMARKS Used for measuring resistance and voltage. Used for inspecting the fuel tank pressure sensor.

EC(H4DOTC)-2

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Front Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

2. Front Catalytic Converter A: REMOVAL The front catalytic converter is integrated into the center exhaust pipe (front). Refer to “Center Exhaust Pipe” for removal procedures.

B: INSTALLATION The front catalytic converter is integrated into the center exhaust pipe (front). Refer to “Center Exhaust Pipe” for installation procedures.

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting.

EC(H4DOTC)-3

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Rear Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

3. Rear Catalytic Converter A: REMOVAL The rear catalytic converter is integrated into the center exhaust pipe (front). Refer to “Center Exhaust Pipe” for removal procedures.

B: INSTALLATION The rear catalytic converter is integrated into the center exhaust pipe (front). Refer to “Center Exhaust Pipe” for installation procedures.

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting.

EC(H4DOTC)-4

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

4. Canister

5) Remove the clip holding the rear wiring harness.

A: REMOVAL 1) Remove the rear wheel LH. 2) Lift up the vehicle. 3) Remove the rear mud guard LH. 4) Disconnect the quick connectors of the vent tube (A), canister drain tube (B), charge tube (C) and PCV drain tube (D), and remove the tubes from clips (E). NOTE: Disconnect the quick connector as shown in the figure.

EC-02592

6) Remove the canister from vehicle.

1 2

1 (a) 1 2

EC-02593 (b)

1

EC-02590

7) Disconnect the connector from drain valve.

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C) and PCV drain tube (D)

(A)

(D)

EC-02594 (E) (B)

(C) EC-02591

8) Disconnect the vent tube (A), canister drain tube (B), charge tube (C) and PCV drain tube (D) from canister, and remove the canister drain tube and PCV drain tube (D) from clip (E).

EC(H4DOTC)-5

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

NOTE: Disconnect the quick connector as shown in the figure. 1 2

B: INSTALLATION 1) Connect the vent tube (A), canister drain tube (B), charge tube (C) and PCV drain tube (D) to canister, and install the canister drain tube (B) and PCV drain tube (D) to clips (E). CAUTION: • Make sure there are no damage or dust on connections. If necessary, clean the seal surface of the pipe. • Make sure that the quick connector is securely connected.

1 (a) 1 2

1

(b)

EC-02590

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C) and PCV drain tube (D)

(B) (A) (D)

(C)

(E)

EC-02595

EC(H4DOTC)-6

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

NOTE: Connect the quick connector as shown in the figure.

2) Connect the connector to the drain valve.

EC-02594

3) Install the canister to the vehicle.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

(a)

(b)

EC-02596

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C) and PCV drain tube (D)

(B) (A) (D)

EC-02593

4) Secure the rear wiring harness with clip. (C)

(E)

EC-02592 EC-02595

5) Attach all tubes to clips (E), and connect the quick connectors of the vent tube (A), canister drain tube (B), charge tube (C) and PCV drain tube (D).

EC(H4DOTC)-7

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

CAUTION: • Make sure there are no damage or dust on connections. If necessary, clean the seal surface of the pipe. • Make sure that the quick connector is securely connected.

C: INSPECTION 1) Check that the canister has no deformation, cracks or other damages. 2) Check that the tube has no cracks, damage or loose part.

NOTE: Connect the quick connector as shown in the figure.

(a)

(b)

EC-02596

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C) and PCV drain tube (D)

(A)

(D)

(E) (B)

(C) EC-02591

6) Install the rear mud guard LH. 7) Lower the vehicle. 8) Install the rear wheel LH.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb)

EC(H4DOTC)-8

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Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

5. Purge Control Solenoid Valve A: REMOVAL

6) Remove the nut securing the purge control solenoid valve 1 to the solenoid valve bracket assembly.

1. PURGE CONTROL SOLENOID VALVE 1 1) Remove the collector cover. 2) Disconnect the ground cable from battery.

EC-02583

IG-02107

7) Disconnect the connector (A) and evaporation hose (B), and then remove the purge control solenoid valve 1. (B)

3) Remove the intercooler. 4) Remove the bolt securing the solenoid valve bracket assembly from intake manifold.

(A)

EC-02540

2. PURGE CONTROL SOLENOID VALVE 2 1) Remove the collector cover. 2) Disconnect the ground cable from battery. EC-02581

5) Remove the bolts securing the PCV pipe and engine harness from intake manifold.

IG-02107

3) Remove the intercooler. EC-02582

EC(H4DOTC)-9

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Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

4) Remove the bolt securing the solenoid valve bracket assembly from intake manifold.

B: INSTALLATION 1. PURGE CONTROL SOLENOID VALVE 1 Install in the reverse order of removal. NOTE: Connect the evaporation hose as shown in the figure. (A)

EC-02581

5) Remove the bolts securing the PCV pipe and engine harness from intake manifold.

(c)

(a)

(B)

EC-02582

6) Remove the nut securing the purge control solenoid valve 2 to the solenoid valve bracket assembly.

(c)

(A) (B) (a) (b) (c)

EC-02584

7) Disconnect the connector (A) and evaporation hose (B), and then remove the purge control solenoid valve 2. (A)

(B)

EC-02542

EC(H4DOTC)-10

(b)

Purge control solenoid valve 1 Purge control solenoid valve 2 To intake manifold To intake duct To fuel pipe

EC-02543

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Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

2. PURGE CONTROL SOLENOID VALVE 2

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

Install in the reverse order of removal. NOTE: Connect the evaporation hose as shown in the figure. (A)

EC-02583

(c)

(a)

(B)

EC-02582

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) (c)

(A) (B) (a) (b) (c)

EC-02581

EC(H4DOTC)-11

(b)

Purge control solenoid valve 1 Purge control solenoid valve 2 To intake manifold To intake duct To fuel pipe

EC-02543

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Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

C: INSPECTION

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

1. PURGE CONTROL SOLENOID VALVE 1) Check that the purge control solenoid valve has no deformation, cracks or other damages. 2) Measure the resistance between the purge control solenoid valve terminals.

2 1 EC-02584

EC-02426

Purge control solenoid valve 1 EC-02582

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

Purge control solenoid valve 2

Terminal No.

Standard

1 and 2

32 ±2 Ω (when 20°C (68°F)) 24 ±3 Ω (when 20°C (68°F))

3) Check that air does not come out from (B) when air is blown into (A). • Purge control solenoid valve 1 (B)

(A)

EC-02581 EC-02430

• Purge control solenoid valve 2

(B)

(A)

EC-02550

4) With terminal No. 1 connected to the battery positive terminal and terminal No. 2 to the battery ground terminal, check that air comes out from (B) when air is blown into (A).

EC(H4DOTC)-12

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Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

• Purge control solenoid valve 1

2 1

(B)

(A)

EC-02433

• Purge control solenoid valve 2

2 1

(B)

(A)

EC-02551

2. OTHER INSPECTIONS Check that the evaporation hose has no cracks, damage or loose part.

EC(H4DOTC)-13

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Fuel Level Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

6. Fuel Level Sensor A: REMOVAL For removal procedures, refer to the “FU (H4DOTC)” section.

B: INSTALLATION For installation procedures, refer to the “FU (H4DOTC)” section.

C: INSPECTION For inspection procedures, refer to the “FU(H4DOTC)” section.

EC(H4DOTC)-14

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Fuel Temperature Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

7. Fuel Temperature Sensor

C: INSPECTION

A: REMOVAL

1) Check the fuel temperature sensor for deformation, cracks or other damages. 2) Measure the resistance between fuel temperature sensor terminals.

Fuel temperature sensor is integrated with the fuel level sensor. Refer to “Fuel Level Sensor” for removal procedure.

CAUTION: Make sure of the circuit tester spec and do not apply a voltage of 3 V or more when measuring the resistance. Otherwise the fuel temperature sensor will be damaged.

(A)

1 2 3 4 EC-02585

(A) Fuel temperature sensor

B: INSTALLATION

EC-02452

Refer to “Fuel Level Sensor” for the installation procedure.

Temperature

Terminal No.

–10°C (14°F) 20°C (68°F) 50°C (122°F)

(A)

EC-02585

(A) Fuel temperature sensor

EC(H4DOTC)-15

Standard 9.2±2.2 kΩ (at a set current of 0.5 mA)

2 and 3

2.5±0.2 kΩ (at a set current of 1.0 mA) 0.84+0.06 –0.05 kΩ (at a set current of 1.0 mA)

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Fuel Sub Level Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

8. Fuel Sub Level Sensor A: REMOVAL For removal procedures, refer to the “FU (H4DOTC)” section.

B: INSTALLATION For installation procedures, refer to the “FU(H4DOTC)” section.

C: INSPECTION For inspection procedures, refer to the “FU(H4DOTC)” section.

EC(H4DOTC)-16

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Fuel Tank Pressure Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

9. Fuel Tank Pressure Sensor

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

WARNING: Place “NO OPEN FLAMES” signs near the working area. 1) Disconnect the ground cable from battery.

Tightening torque: 7.35 N·m (0.7 kgf-m, 5.4 ft-lb)

EC-02599

C: INSPECTION IG-02107

2) Open the fuel filler lid and remove the fuel filler cap. 3) Lift up the vehicle. 4) Disconnect connector (A) from fuel tank pressure sensor. 5) Pull out the vacuum hose (B) from vehicle. 6) Remove the fuel tank pressure sensor from the bracket.

1. FUEL TANK PRESSURE SENSOR 1) Check that the fuel tank pressure sensor does not have deformation, cracks or other damages. 2) Connect dry-cell battery positive terminal to terminal No. 3 and dry-cell battery ground terminal to terminal No. 1, circuit tester positive terminal to terminal No. 2 and the circuit tester negative terminal to terminal No. 1. NOTE: • Use new dry-cell batteries. • Using circuit tester, check the voltage of a single dry-cell battery is 1.6 V or more. And also check the voltage of three batteries in series is between 4.8 V and 5.2 V.

(A)

(B)

3 2 1

EC-02597

7) Disconnect the pressure hose from fuel tank pressure sensor and remove the fuel tank pressure sensor. V

1.5V

EC-02598

1.5V

1.5V

4.8 5.2V FU-04486

3) Check the voltage at a normal atmospheric pressure.

EC(H4DOTC)-17

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Fuel Tank Pressure Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

NOTE: The atmospheric pressure at higher altitude is lower than normal. Therefore, the voltage is lower than the standard value. Terminal No.

Standard

2 (+) and 1 (–)

Approx. 2.5 V (when 25°C (77°F))

4) Connect the Mighty Vac to the pressure port (A) on the fuel tank pressure sensor.

(A) EC-02586

5) Check the voltage when generating vacuum and positive pressure using Mighty Vac. CAUTION: Be sure to apply pressure within a range of –10 — 20 kPa (–0.1 — 0.2 kgf/cm2, –1.45 — 2.90 psi). Otherwise the fuel tank pressure sensor will be damaged. Pressure –6.67 kPa (–0.07 kgf/cm2, –0.97 psi) 6.67 kPa (0.07 kgf/cm2, 0.97 psi)

Terminal No.

2 (+) and 1 (–)

Standard Approx. 0.5 V (when 25°C (77°F)) Approx. 4.5 V (when 25°C (77°F))

2. OTHER INSPECTIONS Check that the hose has no cracks, damage or loose part.

EC(H4DOTC)-18

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Pressure Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

10.Pressure Control Solenoid Valve A: REMOVAL 1) Disconnect the ground cable from battery.

C: INSPECTION 1. PRESSURE CONTROL SOLENOID VALVE 1) Check that the pressure control solenoid valve does not have deformation, cracks or other damages. 2) Measure the resistance between pressure control solenoid valve terminals.

2 1 IG-02107

2) Lift up the vehicle. 3) Disconnect connector (A) from the pressure control solenoid valve. 4) Disconnect the PCV drain hose (B), PCV inlet hose (C) and PCV outlet hose (D) from the pressure control solenoid valve. 5) Remove the nuts securing the bracket to the fuel tank and remove the pressure control solenoid valve together with the bracket. (B)

EC-02587

Terminal No. 1 and 2

Standard 20 — 30 Ω

2. OTHER INSPECTIONS Check that the evaporation hose has no cracks, damage or loose part.

(A)

(D)

(C)

EC-02600

6) Remove the pressure control solenoid valve from the bracket.

EC-02601

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 7.35 N·m (0.7 kgf-m, 5.4 ft-lb)

EC(H4DOTC)-19

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Drain Filter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

11.Drain Filter A: SPECIFICATION Drain valve is a non-disassembled part, so do not remove the drain filter from drain valve. Refer to “Canister” for removal and installation procedures.

EC(H4DOTC)-20

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Shut Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

12.Shut Valve

C: INSPECTION

A: REMOVAL

1) Check that the shut valve does not have deformation, cracks or other damages. 2) Check that the evaporation hose has no cracks, damage or loose part.

WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Remove the fuel filler pipe. 2) Remove the shut valve from the fuel filler pipe.

EC-02602

3) Disconnect the evaporation hose from shut valve and remove the shut valve.

EC-02603

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 4.5 N·m (0.5 kgf-m, 3.3 ft-lb)

EC-02602

EC(H4DOTC)-21

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Drain Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

13.Drain Valve A: REMOVAL Drain valve is integrated with canister. Refer to “Canister” for removal procedure.

B: INSTALLATION Refer to “Canister” for the installation procedure.

C: INSPECTION Measure the resistance between drain valve terminals.

2 1

EC-02455

Terminal No. 1 and 2

Standard 20 — 30 Ω

EC(H4DOTC)-22

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PCV Hose Assembly EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

14.PCV Hose Assembly

B: INSTALLATION

A: REMOVAL

1) Install the PCV hose assembly to the cylinder block RH and blow-by pipe assembly and connect the vacuum hose to the intake manifold.

CAUTION: Do not remove except when the hose is broken. 1) Remove the collector cover. 2) Remove the intercooler. 3) Disconnect the vacuum hose from intake manifold and remove the PCV hose assembly from cylinder block RH and blow-by pipe assembly.

NOTE: Use a new clamp for the PCV hose assembly, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS

NOTE: Pinch the clamp of the PCV hose assembly by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp. ST 18353AA000 CLAMP PLIERS

ST

ME-04374

ST

ME-04374

EC-02588

2) Install the intercooler. 3) Install the collector cover.

C: INSPECTION Check the PCV hose assembly for cracks, damage or looseness. EC-02588

EC(H4DOTC)-23

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PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

15.PCV Valve

B: INSTALLATION

A: REMOVAL

1) Connect the vacuum hose (A) and vacuum hose (B) to the PCV valve.

1) Remove the collector cover. 2) Remove the intercooler. 3) Disconnect the vacuum hose (A) and vacuum hose (B) from the PCV valve and remove the PCV valve.

NOTE: Use a new clamp for the vacuum hose (B), fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS

NOTE: Pinch the clamp of the vacuum hose (B) by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp. ST 18353AA000 CLAMP PLIERS

ST

ST ME-04374

(A)

ME-04374 (B)

EC-02589

(A)

2) Install the intercooler. 3) Install the collector cover.

(B)

C: INSPECTION EC-02589

1. PCV VALVE 1) Check that the PCV valve has no deformation, cracks or other damages. 2) Check that air is discharged from (B) when air is blown into (A).

(B)

(A)

EC-02507

EC(H4DOTC)-24

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PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

3) Check that air does not come out from (B) when air is blown into (A).

(A)

(B)

EC-02508

2. OTHER INSPECTIONS Check the vacuum hose for cracks, damage or looseness.

EC(H4DOTC)-25

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PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(H4DOTC)-26

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INTAKE (INDUCTION)

IN(H4DOTC) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Page General Description ...................................................................................2 Air Cleaner Element ...................................................................................7 Air Cleaner Case ........................................................................................8 Air Intake Boot ..........................................................................................10 Air Intake Duct ..........................................................................................12 Intake Duct ...............................................................................................13 Intercooler ................................................................................................17 Turbocharger ............................................................................................20 Oil Catch Tank .........................................................................................23 Scavenge Pump .......................................................................................24 Air By-pass Valve .....................................................................................25 Resonator Chamber .................................................................................27

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General Description INTAKE (INDUCTION)

1. General Description A: COMPONENT 1. AIR CLEANER T1

(1) (3)

(2)

(12) (4)

T2

(13)

T4 (5) (6) T4

T3

T2 (12)

(7) (8)

(9)

(14) (11)

T4

(15)

(12)

(10)

T2 (17) (16)

T5

(12)

T4

T2 IN-02673

(1) (2) (3) (4) (5) (6) (7) (8)

Mass air flow and intake air temperature sensor Air cleaner case (rear) Clip Air cleaner element Air cleaner case (front) Cushion Spacer Cushion

(9)

Air intake duct

(17)

(10) (11) (12) (13) (14) (15) (16)

Clip Resonator chamber Clamp Air intake boot A Turbo duct Air intake boot B Cushion

Tightening torque:N·m (kgf-m, ft-lb) T1: 1 (0.1, 0.7) T2: 2.5 (0.3, 1.8) T3: 6 (0.6, 4.4) T4: 7.5 (0.8, 5.5) T5: 18 (0.8, 13.3)

IN(H4DOTC)-2

Duct bracket

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General Description INTAKE (INDUCTION)

2. INTAKE DUCT T2

(15)

(13)

T3

(21)

(12)

(8)

(8) (8) (21)

(8)

(8)

(20)

(14)

(18) (18) A B

(8)

(21)

D

C

E F

A B

H

G

(18)

T3

I

T3

(18) (16)

C D

I

G H

(10)

(8)

(18)

(11)

E F

T3 (17)

(18)

(B) (9)

(5) J

L

(7)

(6)

(8)

(21)

K

T1

(A) (3)

(4) T2

(19)

(2)

J L

(1)

K

IN-02721

(A)

To Oil catch tank

(B)

To air by-pass valve

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Intake duct Boost hose ASSY Air control hose Wastegate control solenoid valve Vacuum hose A Vacuum hose B Vacuum hose C Clamp Vacuum hose D

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Hose clip stay ASSY Vacuum control hose Blow-by pipe PCV pipe Blow-by pipe ASSY A PCV hose ASSY Blow-by pipe ASSY B Water pipe ASSY Clamp

IN(H4DOTC)-3

(19) (20) (21)

O-ring Clamp Clamp

Tightening torque:N·m (kgf-m, ft-lb) T1: 1 (0.1, 0.7) T2: 6.4 (0.7, 4.7) T3: 6.5 (0.7, 4.8)

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General Description INTAKE (INDUCTION)

3. INTERCOOLER

(9) T1 T2

(5) (10)

(3) (4)

T2 (5)

T1

(1) (6)

(5)

(13)

T1

(12)

T2

(14) (11)

(2) (8)

(7)

(15)

T2

T1 (14)

IN-02722

(1) (2) (3) (4) (5) (6) (7)

Intercooler Clip SPACER Cushion Clamp Intake duct A Intercooler stay RH

(8) (9) (10) (11) (12) (13) (14)

Intercooler stay LH Cushion Intake duct B O-ring Clamp Air by-pass valve Clip

IN(H4DOTC)-4

(15) Intake boot

Tightening torque:N·m (kgf-m, ft-lb) T1: 3 (0.3, 2.2) T2: 16 (1.6, 11.8)

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General Description INTAKE (INDUCTION)

4. TURBOCHARGER (3) T3 (2) (5)

(4)

T1

(4)

(6) (1)

(7)

(8) (7)

(7)

T5 (13)

(10) (11) (7) T4

(9) T1

(10)

(12) (14)

(15) T1

T1 T2

(1) (2) (3) (4) (5) (6) (7) (8)

Turbocharger Oil inlet pipe Union bolt Gasket Boost hose ASSY Gasket Gasket Water pipe connector

(9) (10) (11) (12) (13) (14) (15)

Water pipe Union bolt Exhaust stay Exhaust cover Gasket Oil catch tank Oil catch tank stay

IN(H4DOTC)-5

IN-02676

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 10.5 (1.1, 7.7) T3: 16 (1.6, 11.8) T4: 31.5 (3.2, 23.2) T5: 36.5 (3.7, 26.9)

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General Description INTAKE (INDUCTION)

B: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.

C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 18353AA000

DESCRIPTION CLAMP PLIERS

REMARKS • Used for removing and installing the PCV hose. • This tool is made by the French company CAILLAU. (code) 54.0.000.205 To make it easier to obtain, it has been provided with a tool number.

ST18353AA000

2. GENERAL TOOL TOOL NAME Mighty Vac

REMARKS Used for checking waste gate actuator and air by-pass valve.

IN(H4DOTC)-6

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Air Cleaner Element INTAKE (INDUCTION)

2. Air Cleaner Element

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Remove the suction hose from intake duct and air cleaner case (rear).

CAUTION: Be sure to use SUBARU genuine air cleaner element depending on the engine type when replacing the air cleaner elements. Using other air cleaner element may affect the engine performance. NOTE: • Check that there are no foreign objects in the air cleaner case. • If the protrusion of the air cleaner case (rear) is removed when removing the air cleaner element, align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.

IN-02679

IN-02723

2) Remove the clip (A) from the air cleaner case (front).

(A)

C: INSPECTION 1) Check that the air cleaner element has no deformation, cracks or other damages. 2) Check the air cleaner element for excessive dirt.

IN-02724

3) Open the air cleaner case to remove the air cleaner element.

IN-02725

IN(H4DOTC)-7

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Air Cleaner Case INTAKE (INDUCTION)

3. Air Cleaner Case

6) Remove the clip (D) from the air cleaner case (front), and remove the air cleaner case (rear).

A: REMOVAL 1) Disconnect the ground cable from battery.

(C)

(B) (A)

(D)

IG-02107

2) Remove the air intake duct. 3) Remove the suction hose from intake duct and air cleaner case (rear).

IN-02726

7) Remove the air cleaner element. 8) Remove bolts (A) and nuts (B) which secure the air cleaner case (front) to the body, and remove the air cleaner case (front). (B)

(A)

IN-02727

B: INSTALLATION 1) Install the bolt (A) and nut (B) which secure the air cleaner case (front) to the body.

Tightening torque: Bolt (A) 6 N·m (0.6 kgf-m, 4.4 ft-lb) Nut (B) 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) (B) IN-02723

4) Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B) which holds the mass air flow and intake air temperature sensor harness. 5) Loosen the clamp (C) which holds the air intake boot.

(A)

IN-02727

2) Install the air cleaner element. 3) Install the air intake case (rear).

IN(H4DOTC)-8

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Air Cleaner Case INTAKE (INDUCTION)

NOTE: When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.

7) Install the suction hose to intake duct and air cleaner case (rear).

IN-02679

4) Install the clip (A) to the air cleaner case (front). 5) Hold the mass air flow and intake air temperature sensor harness with the clip (B), and connect the connector (C) to the mass air flow and intake air temperature sensor. (C)

(B) IN-02723

8) Install the air intake duct. 9) Connect the ground cable to battery. (A)

IN-02728

6) Tighten the clamp which secures the air intake boot.

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb) IG-02107

C: INSPECTION Check that the air cleaner case has no deformation, cracks or other damages.

IN-02729

IN(H4DOTC)-9

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Air Intake Boot INTAKE (INDUCTION)

4. Air Intake Boot

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Disconnect the ground cable from battery.

NOTE: When installing the air intake boot to the vehicle, pay attention to the mounting hole position, and align the protrusion for stopping rotation of cushion to the cutout portion on the turbo duct.

(B)

IG-02107

(A)

2) Remove the air intake duct. 3) Remove the air cleaner case. 4) Lift up the vehicle. 5) Remove the under cover. 6) Remove the intake duct from the air intake boot.

(E) (G) (F) (D) (G) (F)

(C)

IN-02730

7) Lower the vehicle. 8) Remove the nuts which secure the air intake boot to the vehicle, and remove the air intake boot from the upper side of the vehicle.

(A) (B) (C) (D) (E) (F) (G)

IN-02691

Attachment hole Not used Turbo duct Cushion Duct bracket Cutout portion Protrusion portion

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

IN-02685

IN-02685

IN(H4DOTC)-10

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Air Intake Boot INTAKE (INDUCTION)

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb)

IN-02730

C: DISASSEMBLY Remove the air intake boot from the turbo duct.

IN-02686

D: ASSEMBLY Install the air intake boot to the turbo duct.

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb)

IN-02686

E: INSPECTION Check that the air intake boot and turbo duct have no cracks, damage or loose part.

IN(H4DOTC)-11

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Air Intake Duct INTAKE (INDUCTION)

5. Air Intake Duct A: REMOVAL Remove the clip which secures air intake duct then remove the air intake duct.

IN-02731

B: INSTALLATION Install in the reverse order of removal.

C: INSPECTION 1) Check that the air intake duct has no deformation, cracks or other damages. 2) Inspect that no foreign objects are mixed in the air intake duct.

IN(H4DOTC)-12

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Intake Duct INTAKE (INDUCTION)

6. Intake Duct

7) Disconnect the connector from the wastegate control solenoid valve.

A: REMOVAL 1) Remove the collector cover. 2) Disconnect the ground cable from battery.

IN-02763

IG-02107

3) Disconnect the vacuum hose from PCV pipe.

8) Loosen the clamp (A) securing the air intake boot to the intake duct, and remove the air intake boot from intake duct. 9) Disconnect the vacuum hose (B) from intake duct, and unlock the clip (C) securing the air bypass valve to the intake duct. NOTE: Pinch the clamp of the vacuum hose (B) by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp. ST 18353AA000 CLAMP PLIERS

IN-02732

ST

4) Disconnect the vacuum hose (A) from blow-by pipe and remove the vacuum hose (A) and vacuum hose (C). (C) (A) ME-04374 (B) (B)

(C)

IN-02733

5) Lift up the vehicle. 6) Remove the under cover. (A)

IN-02773

10) Disconnect the air control hose (A).

IN(H4DOTC)-13

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Intake Duct INTAKE (INDUCTION)

11) Remove the bolts which secure the intake duct to the turbocharger, and remove the intake duct.

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb)

(A)

IN-02735

B: INSTALLATION 1) Install the bolts which secure the intake duct to the turbocharger, and connect the air control hose (A).

IN-02734

3) Connect the connector to the wastegate control solenoid valve.

NOTE: • Use new O-rings. • Be careful not to pinch the O-ring.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) IN-02763

4) Install the under cover. 5) Lower the vehicle. 6) Install the vacuum hose (A) and vacuum hose (C) to the clip (B), and connect the vacuum hose (A) to the blow-by pipe.

(A)

IN-02735

2) Install the air by-pass valve and air intake boot to the intake duct, and connect the vacuum hose to the intake duct. NOTE: Use a new clamp for the vacuum hose, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS ST

ME-04374

IN(H4DOTC)-14

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Intake Duct INTAKE (INDUCTION)

NOTE: Install the vacuum hose as shown in the figure.

8) Connect the ground cable to battery.

(b)

(a)

(c) A A IG-02107

B C

B

9) Install the collector cover.

C

C: DISASSEMBLY

D D

1) Remove the vacuum hose (A) and vacuum hose (B) from intake duct.

(e) E

E

(f) F

F

(B)

(d)

(A) IN-02736

(a) Blow-by pipe (b) PCV pipe (c) (d) (e) (f)

IN-02764

Hose clip stay ASSY Intake duct Vacuum hose (C) Vacuum hose (A)

2) Remove the wastegate control solenoid valve and air control hose from the intake duct.

(C) (A)

(B) IN-02765

IN-02733

7) Connect the vacuum hose to PCV pipe.

IN-02732

IN(H4DOTC)-15

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Intake Duct INTAKE (INDUCTION)

D: ASSEMBLY 1) Install the wastegate control solenoid valve and air control hose to the intake duct. NOTE: Use new O-rings.

Tightening torque: 1 N·m (0.1 kgf-m, 0.7 ft-lb)

IN-02765

2) Install the vacuum hose (A) and vacuum hose (B) from intake duct.

(B)

(A)

IN-02764

E: INSPECTION 1) Check that the intake duct, PCV pipe and blowby pipe have no deformation, cracks or other damages. 2) Check that the vacuum hose and air control hose have no cracks, damage or loose part.

IN(H4DOTC)-16

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Intercooler INTAKE (INDUCTION)

7. Intercooler

(1) Remove the suction hose from intake duct.

A: REMOVAL 1) Remove the collector cover. 2) Remove the clamp (A) which holds the intake duct to the intercooler, and remove bolts which secure the intercooler to the intercooler stay LH.

IN-02740

(2) Disconnect the connector (A) from power steering pump, and remove the power steering pump together with the power steering pump bracket from engine and stopper rod.

(A) IN-02737

(A)

3) Loosen the clamp (A) securing the intake duct to the intercooler, and remove the bolt securing the intercooler to the intercooler stay RH to remove the intercooler.

IN-02741

(A)

IN-02738

4) Remove the brake booster vacuum hose from the clip (A), and remove the intercooler stay RH and intercooler stay LH.

(3) Mount the power steering pump together with the power steering pump bracket on RH side wheel apron. 8) Remove the radiator sub fan motor assembly.

9) Remove the engine coolant hose from the clip (A). 10) Remove the bolts which secure the intake duct to the turbocharger, and remove the air by-pass valve from the intake duct. (A)

(A)

IN-02739

5) Remove the V-belts. 6) Remove the generator. 7) Remove the power steering pump.

IN(H4DOTC)-17

IN-02696

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Intercooler INTAKE (INDUCTION)

11) Remove the intake duct from intake manifold.

Tightening torque: Refer to “COMPONENT” of “STARTING/ CHARGING SYSTEMS” for the tightening torque.

(A)

IN-02698

B: INSTALLATION 1) Install the intake duct to the intake manifold. IN-02741

(2) Install the suction hose to the intake duct.

IN-02698

2) Attach the engine coolant hose to the clip (A). 3) Install the air by-pass valve to the intake duct, and install the bolts which secure the intake duct to the turbocharger. NOTE: • Use new O-rings. • Be careful not to pinch the O-ring.

Tightening torque: T1: 3 N·m (0.3 kgf-m, 2.2 ft-lb) T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

IN-02740

6) Install the generator. 7) Install the V-belts. 8) Install the intercooler stay RH and intercooler stay LH, and install the brake booster vacuum hose to the clip (A).

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

(A)

(A)

T1 T2 IN-02697

4) Install the radiator sub fan motor assembly.

5) Install the power steering pump. (1) Install the power steering pump together with the power steering pump bracket to engine and stopper rod, and connect the connector (A) to the power steering pump.

IN-02739

9) Place the intercooler and attach the bolt to secure the intercooler to the intercooler stay RH. And tighten the clamp to secure the intake duct to the intercooler.

IN(H4DOTC)-18

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Intercooler INTAKE (INDUCTION)

Tightening torque: T1: 3 N·m (0.3 kgf-m, 2.2 ft-lb) T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T2

T1

IN-02742

10) Install the bolts which secure the intercooler to the intercooler stay LH, and tighten the clamp which holds the intake duct to the intercooler.

Tightening torque: T1: 3 N·m (0.3 kgf-m, 2.2 ft-lb) T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb) T2

T1 IN-02743

11) Install the collector cover.

C: INSPECTION 1) Check that the intercooler and intercooler stay have no deformation, cracks or other damages. 2) Check that the intake duct has no cracks, damage or loose part.

IN(H4DOTC)-19

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Turbocharger INTAKE (INDUCTION)

8. Turbocharger

4) Remove the exhaust cover from the turbocharger.

A: REMOVAL Remove the turbo charger and front exhaust pipe as a unit. Refer to “Front Exhaust Pipe” for the removal procedure.

B: INSTALLATION Refer to “Front Exhaust Pipe” for the installation procedure.

IN-02707

5) Remove the exhaust stay from the turbocharger.

C: DISASSEMBLY 1) Remove the oil inlet pipe from the turbocharger.

IN-02708

D: ASSEMBLY 1) Install the exhaust stay to the turbocharger. IN-02771

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

2) Remove the water pipe from the turbocharger.

IN-02708 IN-02768

3) Remove the water pipe connector from the turbocharger.

2) Install the exhaust cover to the turbocharger.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

IN-02769

IN(H4DOTC)-20

IN-02707

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Turbocharger INTAKE (INDUCTION)

3) Install the water pipe connector to the turbocharger. NOTE: Use a new gasket.

E: INSPECTION 1. WASTE GATE ACTUATOR 1) Remove the collector cover. 2) Remove the front exhaust pipe. 3) Remove the exhaust pipe cover.

Tightening torque: 36.5 N·m (3.7 kgf-m, 26.9 ft-lb)

IN-02769

4) Install the water pipe to the turbocharger. NOTE: Use a new gasket.

EX-02594

4) Remove the boost hose (B) from the waste gate actuator (A) of the turbocharger, and connect the Mighty Vac to the waste gate actuator (A).

Tightening torque: 31.5 N·m (3.2 kgf-m, 23.2 ft-lb) (D)

(B) (C)

(A) IN-02770

IN-02768

5) Install the oil inlet pipe to the turbocharger. NOTE: Use a new gasket.

(A) (B) (C) (D)

Waste gate actuator Boost hose Control rod Control rod stroke

5) Pressurize slowly with the Mighty Vac, and check the pressure when the control rod stroke (D) becomes 2 mm (0.08 in). If it is not within the standard, replace the turbocharger assembly.

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

CAUTION: Do not pressurize over 85.2 kPa (0.87 kgf/cm2, 12.35 psi) to prevent damaging the waste gate actuator.

T2

T1

IN-02772

Operating pressure (control rod stroke 2 mm (0.08 in)): Standard 70.8 — 76.7 kPa (0.72 — 0.78 kgf/cm2, 10.27 — 11.12 psi) 6) After inspection, install the related parts in the reverse order of removal.

IN(H4DOTC)-21

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Turbocharger INTAKE (INDUCTION)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

EX-02594

2. OTHER INSPECTIONS 1) Check that the turbocharger and pipe have no deformation, cracks or other damages. 2) Check that the hose has no cracks, damage or loose part. 3) Check that there are no oil leaks or water leaks from the pipe attachment section.

IN(H4DOTC)-22

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Oil Catch Tank INTAKE (INDUCTION)

9. Oil Catch Tank

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Lift up the vehicle. 2) Remove the under cover. 3) Remove the engine cover.

NOTE: • Use a new gasket. • When installing the oil catch tank, tighten to the specified torque in the alphabetical order shown in the figure. • Use a new clamp for the vacuum hose, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS ST

IN-02746

4) Disconnect vacuum hose (A) and oil outlet hose (B) from the oil catch tank. NOTE: Pinch the clamp of the vacuum hose (A) by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp. ST 18353AA000 CLAMP PLIERS

ME-04374

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 10.5 N·m (1.1 kgf-m, 7.7 ft-lb)

ST

T1 (a) (b)

T2

(c)

IN-02767

ME-04374

5) Remove bolts and nuts which secure the oil catch tank to the turbocharger and oil catch tank stay, and remove the oil catch tank.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(A)

(B)

IN-02746 IN-02747

C: INSPECTION 1) Check that the oil catch tank does not have deformation, cracks or damage. 2) Check that the vacuum hose and oil outlet hose have no cracks, damage or loose part.

IN(H4DOTC)-23

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Scavenge Pump INTAKE (INDUCTION)

10.Scavenge Pump A: REMOVAL For removal procedures, refer to LU (H4SO) section.

B: INSTALLATION For installation procedures, refer to LU (H4SO) section.

C: INSPECTION Refer to LU (H4SO) for inspection procedures.

IN(H4DOTC)-24

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Air By-pass Valve INTAKE (INDUCTION)

11.Air By-pass Valve

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Remove the collector cover. 2) Disconnect the vacuum control hose from the PCV pipe, and remove the vacuum control hose from the clip (A).

Tightening torque: 3 N·m (0.3 kgf-m, 2.2 ft-lb)

IN-02712

(A) IN-02744

3) Loosen the clamp which holds the air by-pass valve to the intake duct.

C: INSPECTION 1. AIR BY-PASS VALVE 1) Check that the air by-pass valve has no deformation, cracks or other damages. 2) Connect the Mighty Vac to the nipple (A) of the air by-pass valve. (A)

IN-02712

4) Lift up the vehicle. 5) Remove the under cover. 6) Remove the air by-pass valve from the intake duct.

IN-02715

3) Using the Mighty Vac, generate the negative pressure to –93.3 kPa (–0.95 kgf/cm2, –13.5 psi). Check that the Mighty Vac gauge needle holds 10 seconds without falling by –92.6 kPa (–0.94 kgf/ cm2, –13.4 psi).

IN-02745

IN(H4DOTC)-25

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Air By-pass Valve INTAKE (INDUCTION)

4) Set a dial gauge to the end of valve rod of the air by-pass valve.

IN-02716

5) Using the Mighty Vac, generate the negative pressure, and check the pressure when dial gauge needle (valve stroke) shows 0.5 mm (0.02 in). If it is not within the standard, replace the air by-pass valve.

Opening pressure (valve stroke 0.5 mm (0.02 in)): Standard –49.3 — –57.3 kPa (–0.50 — –0.58 kgf/cm2, –7.15 — –8.31 psi)

2. OTHER INSPECTIONS Check that the vacuum hose and air by-pass pipe have no cracks, damage or loose part.

IN(H4DOTC)-26

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Resonator Chamber INTAKE (INDUCTION)

12.Resonator Chamber A: REMOVAL The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to “Air Cleaner Case” for removal procedure.

B: INSTALLATION The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to “Air Cleaner Case” for installation procedure.

C: INSPECTION Check that the resonator chamber has no deformation, cracks or other damages.

IN(H4DOTC)-27

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Resonator Chamber INTAKE (INDUCTION)

IN(H4DOTC)-28

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MECHANICAL

ME(H4DOTC) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Page General Description ...................................................................................2 Compression ............................................................................................21 Idle Speed ................................................................................................22 Ignition Timing ..........................................................................................23 Intake Manifold Vacuum ...........................................................................24 Engine Oil Pressure .................................................................................25 Fuel Pressure ...........................................................................................26 Valve Clearance .......................................................................................27 Engine Assembly .....................................................................................31 Engine Mounting ......................................................................................38 Preparation for Overhaul ..........................................................................41 V-belt ........................................................................................................42 Crank Pulley .............................................................................................44 Timing Belt Cover .....................................................................................46 Timing Belt ...............................................................................................51 Cam Sprocket ..........................................................................................60 Crank Sprocket ........................................................................................61 Camshaft ..................................................................................................62 Cylinder Head ..........................................................................................72 Cylinder Block ..........................................................................................81 Intake and Exhaust Valve ......................................................................105 Piston .....................................................................................................106 Connecting Rod .....................................................................................107 Crankshaft ..............................................................................................108 Engine Trouble in General .....................................................................109 Engine Noise ..........................................................................................115

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General Description MECHANICAL

1. General Description A: SPECIFICATION Model

2.5 L Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine

Cylinder arrangement

Belt driven, double overhead camshaft, 4-valve/ cylinder mm (in) 99.5 × 79.0 (3.92 × 3.11) 2,457 (149.94) cm3 (cu in) 9.5

Valve system mechanism Bore × Stroke Displacement Compression ratio Compression pressure (at 200 — 300 rpm) Number of piston rings

kPa (kg/cm2, psi) Standard

Pressure ring: 2, Oil ring: 1 Open

Intake valve timing Close Engine Open Exhaust valve timing Close

Valve clearance

mm (in)

Idle speed (gear shift lever in neutral position) Ignition order Ignition timing

981 — 1,177 (10 — 12, 142 — 171)

Max. retard Min. advance Max. retard

ATDC 5° BTDC 35° ABDC 65°

Min. advance

ABDC 25°

Max. retard

BBDC 32°

Min. advance

BBDC 72°

Max. retard Min. advance

ATDC 28° BTDC 12°

Inspection value

Intake

0.20+0.04 –0.06 (0.0079+0.0016 –0.0024)

Exhaust

Adjustment value

Intake Exhaust No Standard load

0.35±0.05 (0.0138±0.0020) 0.20+0.01 –0.03 (0.0079+0.0004 –0.0012) 0.35±0.02 (0.0138±0.0008)

rpm

A/C ON

700±100

Standard

700 — 850±100

BTDC/rpm Standard

1→3→2→4 15°±10°/700

ME(H4DOTC)-2

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General Description MECHANICAL

NOTE: OS: Oversize Belt tension adjuster

US: Undersize

Adjuster rod protrusion amount

mm (in)

Bending limit Cam lobe height Camshaft

Cam base circle diameter Journal O.D.

Cylinder head

Valve seat

Valve guide

Intake mm (in) Exhaust mm (in) Front mm (in) Center, rear mm (in) mm (in)

Oil clearance Thrust clearance Warping limit (Mating surface with cylinder block)

Grinding limit Standard height Seating angle between valve and valve seat

mm (in) Standard Standard Standard Standard Standard Standard Standard mm (in)

0.035 (0.0014)

mm (in) mm (in)

0.3 (0.012) 127.5 (5.02) 90°

mm (in)

Intake Exhaust

Standard Standard

0.6 — 1.4 (0.024 — 0.055) 1.2 — 1.8 (0.047 — 0.071)

Clearance between the valve guide and valve stem

mm (in)

Intake Exhaust

Standard Standard mm (in)

0.030 — 0.057 (0.0012 — 0.0022) 0.040 — 0.067 (0.0016 — 0.0026) 6.000 — 6.012 (0.2362 — 0.2367)

mm (in)

Intake Exhaust mm (in)

5.955 — 5.970 (0.2344 — 0.2350) 5.945 — 5.960 (0.2341 — 0.2346) 15.8 — 16.2 (0.622 — 0.638)

Inside diameter

Valve guide protrusion amount Head edge thickness

Intake mm (in) Exhaust

Overall length

mm (in)

Valve

Standard Standard

Intake Exhaust

Free length

mm (in)

Tension/spring height

mm (in) Standard

0.019 — 0.057 (0.0007 — 0.0022)

Lift

Warping limit (Mating surface with cylinder head)

Cylinder block

Grinding limit Standard height Taper Out-of-roundness Cylinder to piston clearance at 20°C (68°F):

104.4 (4.110) 104.65 (4.1201) 47.32 (1.863)

mm (in) Standard mm (in) Standard

N (kgf, lb)/mm (in)

Squareness Outer diameter Inner diameter of valve lifter mating surface Clearance between valve lifter and valve lifter mating surface

1.0 — 1.4 (0.039 — 0.055) 1.3 — 1.7 (0.051 — 0.067)

205 — 235 (20.90 — 23.96, 46.09 — 52.84)/36.0 (1.417) 426 — 490 (43.44 — 49.96, 95.78 — 110.17)/26.5 (1.043) 2.5°, 2.1 mm (0.083 in) or less 34.959 — 34.975 (1.3763 — 1.3770) 34.994 — 35.016 (1.3777 — 1.3786)

Set

Valve lifter

0.020 (0.00079) 46.55 — 46.65 (1.833 — 1.837) 45.85 — 45.95 (1.805 — 1.809) 37.0 (1.457) 37.946 — 37.963 (1.4939 — 1.4946) 29.946 — 29.963 (1.1790 — 1.1796) 0.037 — 0.072 (0.0015 — 0.0028) 0.068 — 0.116 (0.0027 — 0.0047)

Contacting width of valve and valve seat

Valve stem outer diameter

Valve spring

5.2 — 6.2 (0.205 — 0.244)

mm (in)

0.025 (0.0098)

mm (in) mm (in) mm (in) Standard mm (in) Standard

0.1 (0.004) 201.0 (7.91) 0.015 (0.0006) 0.010 (0.0004)

mm (in) Standard

–0.010 — 0.010 (–0.00039 — 0.00039)

Cylinder inner diameter boring limit (diameter)

mm (in)

ME(H4DOTC)-3

To 100.005 (3.9372)

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General Description MECHANICAL Piston grade point Piston

mm (in) A Standard B mm (in) 0.25 (0.0098) OS 0.50 (0.0197) OS

Outer diameter

Piston pin must be fitted into position with thumb at 20°C (68°F).

Degree of fit Piston pin

Clearance between piston pin hole and piston pin

Bushing of small end

Top ring Standard mm (in) Second ring Standard Oil ring Standard

Clearance between piston ring and piston ring groove

mm (in)

Top ring Standard Second ring Standard

Bend or twist per 100 mm (3.94 in) in length

mm (in)

Thrust clearance Oil clearance

mm (in) Standard mm (in) Standard

Bearing size (Thickness at center)

Service limit

Standard 0.03 (0.0012) US mm (in) 0.05 (0.0020) US 0.25 (0.0098) US

Clearance between piston pin and bushing Bending limit

mm (in) Standard mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

Out-of-roundness Cylindricality Grinding limit (dia.) Out-of-roundness Crank journal Cylindricality Grinding limit (dia.) Standard 0.03 (0.0012) US Crank pin outer diameter mm (in) 0.05 (0.0020) US 0.25 (0.0098) US Standard 0.03 (0.0012) US Crank journal outer diameter mm (in) 0.05 (0.0020) US 0.25 (0.0098) US Crank pin

Crankshaft and crankshaft bearing

mm (in) Standard

Piston ring gap Piston ring

Connecting rod and connecting rod bearing

#1, #3 Bearing size (Thickness at center)

mm (in) #2, #4, #5

Thrust clearance Oil clearance

38.2 (1.50) 99.505 — 99.515 (3.9175 — 3.9179) 99.495 — 99.505 (3.9171 — 3.9175) 99.745 — 99.765 (3.9270 — 3.9278) 99.995 — 100.015 (3.9368 — 3.9376)

0.004 — 0.008 (0.0002 — 0.0003) 0.20 — 0.25 (0.0079 — 0.0098) 0.37 — 0.52 (0.015 — 0.0203) 0.20 — 0.50 (0.0079 — 0.0197) 0.040 — 0.080 (0.0016 — 0.0031) 0.030 — 0.070 (0.0012 — 0.0028) 0.1 (0.0039) 0.070 — 0.330 (0.0028 — 0.0130) 0.017 — 0.045 (0.0007 — 0.0018) 1.490 — 1.506 (0.0587 — 0.0593) 1.504 — 1.512 (0.0592 — 0.0595) 1.514 — 1.522 (0.0596 — 0.0599) 1.614 — 1.622 (0.0635 — 0.0639) 0 — 0.022 (0 — 0.0009) 0.035 (0.0014) 0.003 (0.0001) 0.004 (0.0002) To 51.750 (2.0374) 0.005 (0.0002) 0.006 (0.0002) To 59.758 (2.3527) 51.976 — 52.000 (2.0463 — 2.0472) 51.954 — 51.970 (2.0454 — 2.0461) 51.934 — 51.950 (2.0447 — 2.0453) 51.734 — 51.750 (2.0368 — 2.0374) 59.984 — 60.008 (2.3616 — 2.3625) 59.962 — 59.978 (2.3607 — 2.3613) 59.942 — 59.958 (2.3599 — 2.3605) 59.742 — 59.758 (2.3520 — 2.3527)

Standard 0.03 (0.0012) US 0.05 (0.0020) US 0.25 (0.0098) US

1.998 — 2.015 (0.0787 — 0.0793) 2.017 — 2.020 (0.0794 — 0.0795) 2.027 — 2.030 (0.0798 — 0.0799) 2.127 — 2.130 (0.0837 — 0.0839)

Standard 0.03 (0.0012) US 0.05 (0.0020) US 0.25 (0.0098) US mm (in) Standard mm (in) Standard

2.000 — 2.017 (0.0787 — 0.0794) 2.019 — 2.022 (0.0795 — 0.0796) 2.029 — 2.032 (0.0799 — 0.0800) 2.129 — 2.132 (0.0838 — 0.0839) 0.030 — 0.115 (0.0012 — 0.0045) 0.010 — 0.030 (0.00039 — 0.0012)

ME(H4DOTC)-4

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General Description MECHANICAL

B: COMPONENT 1. V-BELT (5) (6)

(4)

(3)

(7)

T4 A (11)

T2

T4

(2)

(8)

T6

T5

A

B

(12)

B

T1 T7

T7

T5

(9) (10) C

(1)

C (13)

T7 T3

ME-04358

(1) (2)

V-belt Collector cover bracket

(8) (9)

Idler pulley ASSY Stopper rod RH

(3) (4) (5) (6) (7)

V-belt tensioner ASSY Power steering pump bracket Generator Generator plate A/C compressor bracket A

(10) (11) (12) (13)

Stopper rod LH A/C compressor A/C compressor bracket B Front cushion rubber

ME(H4DOTC)-5

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: T3: T4: T5: T6: T7:

20 (2.0, 14.8) 22 (2.2, 16.2) 25 (2.5, 18.4) 26.5 (2.7, 19.5) 33 (3.4, 24.3) 36 (3.7, 26.6)

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General Description MECHANICAL

2. TIMING BELT (19)

(1) (2)

T4

T3

(3)

T2 (19) (4)

T3 (20) (9)

(21) (12)

T5

T8

T2

(5)

T1 (6) (8) (20)

T2

(7)

(17)

T6

T7

T1 (22)

T2

(21)

(23)

T2

T8 (10)

T7 (14)

(19)

(20)

T3 T7

(11)

(24) (20)

(13)

T1

(22)

T2 T2 (15)

(16)

T2

T9

(25) (18)

T2 T2 ME-04359

(1) (2) (3) (4) (5) (6)

(13) (14) (15) (16) (17) (18)

Belt idler No. 2 Belt idler Timing belt cover LH Front belt cover Timing belt cover RH Crank pulley

(7) (8) (9) (10) (11)

Timing belt cover No. 2 RH Timing belt guide Crank sprocket Timing belt cover No. 2 LH Tensioner bracket Automatic belt tension adjuster ASSY Belt idler Exhaust cam sprocket RH Intake cam sprocket RH Intake cam sprocket LH Exhaust cam sprocket LH

(19) (20) (21) (22) (23)

Timing belt guide O-ring Intake actuator cover Exhaust actuator cover Belt idler

T4: T5: T6: T7: T8:

(12)

Timing belt

(24)

Hose clip stay ASSY

T9:

ME(H4DOTC)-6

(25)

Oxygen sensor bracket

Tightening torque:N·m (kgf-m, ft-lb) T1: 3.4 (0.3, 2.5) T2: 5 (0.5, 3.7) T3: 6.4 (0.7, 4.7) 9.75 (1.0, 7.2) 24.5 (2.5, 18.1) 25 (2.5, 18.4) 39 (4.0, 28.8)

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General Description MECHANICAL

3. CYLINDER HEAD AND CAMSHAFT (1)

T7 T7

T1 (2) (6) T3

T7

T5 T5 (27)

(8)

T7

(32)

(38)

(33)

(9)

T2

T7 (28) T7

(13)

(4) (7)

(14)

(5) (10) (12) (3) (31)

T6

(23)

(29)

(30) (11) T3

T4

(34) (9)

T1

T1

(15) (16)

(33) (14)

(24) (8)

(37)

T5 (19) (27)

T7 (25)

(26)

(21)

T5 (17)

(32) (27)

(20)

(12) (36)

(18)

(29) (35)

T7

T7 (22)

(11) T4

T6

T7 T7 ME-04224

ME(H4DOTC)-7

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General Description MECHANICAL (1)

Rocker cover RH

(17)

Exhaust camshaft LH

(33)

(2) (3)

Rocker cover gasket RH Front camshaft cap RH

(18) (19)

Front camshaft cap LH Intake camshaft cap LH

(34) (35)

(4) (5)

Intake camshaft cap RH Intake camshaft RH

(20) (21)

Exhaust camshaft cap LH Rocker cover gasket LH

(36) (37)

(6)

(22)

Rocker cover LH

(38)

(7) (8) (9) (10) (11) (12) (13) (14)

Intake oil flow control solenoid valve RH Exhaust camshaft cap RH Gasket Oil return cover Exhaust camshaft RH Cylinder head bolt Oil seal Cylinder head RH Cylinder head gasket

(23) (24) (25) (26) (27) (28) (29) (30)

Oil filler cap Oil filler duct O-ring Oil pipe LH Gasket Oil pipe RH Stud bolt Exhaust oil flow control solenoid valve RH

(15)

Cylinder head LH

(31)

Gasket (RH)

(16)

Intake camshaft LH

(32)

Union bolt with filter (with protrusion)

ME(H4DOTC)-8

Union bolt without filter (without protrusion) Gasket Exhaust oil flow control solenoid valve LH Gasket (LH) Intake oil flow control solenoid valve LH Rear camshaft cap

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 8 (0.8, 5.9) T3: 9 (0.9, 6.6) T4: 10 (1.0, 7.4) T5: 29 (3.0, 21.4) T6: T7:

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General Description MECHANICAL

4. CYLINDER HEAD AND VALVE ASSEMBLY (1)

(11)

(4)

(5)

(6)

(7)

(8)

(9)

(3)

(2)

(11) (4) (12)

(5)

(6)

(7)

(8)

(9)

(4) (10) (6) (7)

(12)

(8) (9)

(4) (10) (6) (7) (8) (9)

ME-04120

(1) (2) (3) (4)

Exhaust valve Intake valve Cylinder head Valve spring seat

(5) (6) (7) (8)

Intake valve oil seal Valve spring Retainer Retainer key

ME(H4DOTC)-9

(9) (10) (11) (12)

Valve lifter Exhaust valve oil seal Intake valve guide Exhaust valve guide

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General Description MECHANICAL

5. CYLINDER BLOCK T2

T2

T5 (33)

(5)

T2

T12

(34) T2

T6

(7)

(1)

(34) (8)

(10)

(30)

(6)

(3)

(29)

T6

T10 T2

(4)

T2

(2)

(28)

(10)

(9) (14) T10

(10)

(3)

(18) (10)

T2 (19)

(32)

(27)

(40) (41)

(38)

(4) (3)

T9

(30)

T10

(37)

(43)

(11)

(10)

T3

T2

(4)

T6

(12) (29)

(35) (15)

T2 T6

(25) T2

T5 (39) (31)

T12

T2 (23)

(17)

(13) T4

T8

(26)

(16) (42) T11

(20)

(36)

T1 (22) (24) (21)

T11

T7 ME-04360

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General Description MECHANICAL (1) (2)

Oil pressure switch Cylinder block RH

(21) (22)

Drain plug Drain plug gasket

(41) (42)

Oil level switch Oil cooler pipe stay

(3) (4)

Service hole plug Gasket

(23) (24)

Oil level gauge guide Oil filter

(43)

O-ring

(5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

Oil separator cover Water by-pass pipe Oil pump Front oil seal Rear oil seal O-ring Service hole cover Cylinder block LH Water pump Baffle plate Oil cooler Oil cooler pipe Connector

(25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37)

Gasket Water pump hose Nipple Seal Washer Seal washer O-ring Gasket Engine rear hanger Oil pump seal Water pump sealing O-ring Oil level gauge

(18)

Oil strainer

(38)

O-ring

(19) (20)

Cylinder block lower Oil pan

(39) (40)

Oil drain pipe O-ring

ME(H4DOTC)-11

Tightening torque:N·m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 6.4 (0.7, 4.7) T3: 10 (1.0, 7.4) T4: First 12 (1.2, 8.9) Second 12 (1.2, 8.9) T5: 16 (1.6, 11.8) T6: 25 (2.5, 18.4) T7: 41.7 (4.3, 30.8) T8: 54 (5.5, 39.8) T9: 69 (7.0, 50.9) T10: 70 (7.1, 51.6) T11: T12:

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General Description MECHANICAL

6. CRANKSHAFT AND PISTON

(1) T2 (8)

(2)

(7)

(3)

(10)

(4) (5) (8)

(11)

(6)

T1

(9)

(13) (11)

(12)

(12) (9) (11)

T1 (6) (8)

(11)

(14)

(5) (4) (3)

(10)

(8)

(7) (17) (16) (15) (16) (15) ME-04101

(1) (2) (3) (4) (5) (6) (7)

Flywheel Ball bearing Top ring Second ring Oil ring Piston Piston pin

(8) (9) (10) (11) (12) (13) (14)

Snap ring Connecting rod bolt Connecting rod Connecting rod bearing Connecting rod cap Crankshaft Woodruff key

ME(H4DOTC)-12

(15) (16) (17)

Crankshaft bearing #1, #3 Crankshaft bearing #2, #4 Crankshaft bearing #5

Tightening torque:N·m (kgf-m, ft-lb) T1: 52 (5.3, 38.4) T2:

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General Description MECHANICAL

7. ENGINE MOUNTING

T5

(3)

(4)

T1 A

B

T2 B

T5 A

(2)

T4

(1) T3

T5

ME-04480

(1) (2)

Front mounting bracket Front cushion rubber

(3) (4)

Engine mounting bracket Turbocharger upper stay

ME(H4DOTC)-13

Tightening torque:N·m (kgf-m, ft-lb) T1: 25 (2.5, 18.4) T2: 33 (3.4, 24.3) T3: 45 (4.6, 33.2) T4: 58 (5.9, 42.8) T5: 60 (6.1, 44.3)

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General Description MECHANICAL

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. • All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings. • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly. • Be careful not to let oil, grease or engine coolant contact the timing belt, clutch disc and flywheel. • All removed parts, if to be reused, should be reinstalled in the original positions and directions. • Bolts, nuts and washers should be replaced with new parts as required. • Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks. • Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use. • Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection. • Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc. • Lift up or lower the vehicle when necessary. Make sure to support the correct positions.

ME(H4DOTC)-14

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General Description MECHANICAL

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 498267600

DESCRIPTION CYLINDER HEAD TABLE

REMARKS • Used for replacing valve guides. • Used for removing and installing valve spring.

498457000

ENGINE STAND ADAPTER RH

Used together with ENGINE STAND (499817100).

498457100

ENGINE STAND ADAPTER LH

Used together with ENGINE STAND (499817100).

498497100

CRANKSHAFT STOPPER

Used for removing and installing flywheel.

ST-498267600

ST-498457000

ST-498457100

ST-498497100

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 498747300

DESCRIPTION PISTON GUIDE

REMARKS Used for installing piston to cylinder.

498857100

VALVE OIL SEAL GUIDE

Used for press-fitting of intake and exhaust valve guide oil seals.

499017100

PISTON PIN GUIDE

Used for installing piston pin, piston and connecting rod.

499037100

CONNECTING ROD BUSHING REMOVER AND INSTALLER

Used for removing and installing connecting rod bushing.

499587100

OIL SEAL INSTALLER

Used for installing oil pump oil seal.

ST-498747300

ST-498857100

ST-499017100

ST-499037100

ST-499587100

ME(H4DOTC)-16

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 499587200

DESCRIPTION CRANKSHAFT OIL SEAL INSTALLER

REMARKS • Used for installing crankshaft oil seal. • Used together with CRANKSHAFT OIL SEAL GUIDE (499597100).

499587600

OIL SEAL INSTALLER

Used for installing the camshaft oil seal.

499597100

CRANKSHAFT OIL SEAL GUIDE

• Used for installing crankshaft oil seal. • Used together with CRANKSHAFT OIL SEAL INSTALLER (499587200).

499597200

OIL SEAL GUIDE

• Used for installing the camshaft oil seal. • Used together with OIL SEAL INSTALLER (499587600).

499718000

VALVE SPRING REMOVER

Used for removing and installing valve spring.

ST-499587200

ST-499587600

ST-499597100

ST-499597200

ST-499718000

ME(H4DOTC)-17

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 499767200

DESCRIPTION VALVE GUIDE REMOVER

REMARKS Used for removing valve guides.

499767400

VALVE GUIDE REAMER

Used for reaming valve guides.

499817100

ENGINE STAND

• Used for disassembling and assembling engine. • Used together with ENGINE STAND ADAPTER RH (498457000) & LH (498457100).

499977100

CRANK PULLEY WRENCH

Used for removing and installing the crank pulley.

499977500

CAM SPROCKET WRENCH

Used for removing and installing intake cam sprocket and exhaust cam sprocket.

ST-499767200

ST-499767400

ST-499817100

ST-499977100

ST-499977500

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 499987500

DESCRIPTION CRANKSHAFT SOCKET

REMARKS Used for rotating crankshaft.

VALVE GUIDE ADJUSTER

Used for installing intake and exhaust valve guides.

PISTON PIN REMOVER ASSY

Used for removing piston pin.

18353AA000

CLAMP PLIERS

• Used for removing and installing the PCV hose. • This tool is made by the French company CAILLAU. (code) 54.0.000.205 To make it easier to obtain, it has been provided with a tool number.

18371AA000

CONNECTOR REMOVER

Used for disconnecting the quick connector on the fuel return hose of the engine compartment (intake manifold).

ST-499987500

18251AA020

ST18251AA020

499097700

ST-499097700

ST18353AA000

ST18371AA000

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 18854AA000

DESCRIPTION ANGLE GAUGE

REMARKS Used for installing the crank pulley.

42099AE000

QUICK CONNECTOR RELEASE

Used for disconnecting quick connector of the engine compartment.

1B022XU0

SUBARU SELECT MONITOR III KIT

Used for each inspection.

ST18854AA000

ST42099AE000

ST1B022XU0

2. GENERAL TOOL Compression gauge Timing light Vacuum gauge

TOOL NAME

REMARKS Used for measuring compression. Used for measuring ignition timing. Used for measuring intake manifold vacuum.

Oil pressure gauge Fuel pressure gauge

Used for measuring engine oil pressure. Used for measuring fuel pressure.

ME(H4DOTC)-20

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Compression MECHANICAL

2. Compression

• If the compression pressure is out of standard, check or adjust the pistons, valves and cylinders.

A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1) Remove the collector cover. 2) After warming-up the engine, turn the ignition switch to OFF. 3) Make sure that the battery is fully charged. 4) Remove the fuse of fuel pump from main fuse box.

Compression (fully open throttle): Standard 981 — 1,177 kPa (10 — 12 kgf/cm2, 142 — 171 psi) Difference between cylinders 49 kPa (0.5 kgf/cm2, 7 psi) or less 13) After inspection, install the related parts in the reverse order of removal.

FU-04800

5) Start the engine and run it until it stalls. 6) After the engine stalls, crank it for five more seconds. 7) Turn the ignition switch to OFF. 8) Remove all spark plugs. 9) Fully open the throttle valve. 10) Check the starter motor for satisfactory performance and operation. 11) Install the compression gauge to the spark plug hole. NOTE: When using a screw-in type compression gauge, the screw should be less than 18 mm (0.71 in) long.

ME-04361

12) Crank the engine by starter motor and read the value when the needle of the compression gauge becomes stable. NOTE: • Perform at least two measurements per cylinder, and make sure that the values are correct.

ME(H4DOTC)-21

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Idle Speed MECHANICAL

3. Idle Speed A: INSPECTION 1) Before checking the idle speed, check the following item: (1) Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the engine idle speed using Subaru Select Monitor. NOTE: • Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. • If idle speed is out of standard, refer to the General Diagnosis Table under “Engine Control System”. (1) Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C and etc. are OFF)

Idle speed (No load and gear shift lever in neutral position): Standard 700±100 rpm (2) Check the idle speed when loaded. (Turn the A/C switch to “ON” and operate the compressor for at least one minute before measurement.) Idle speed (A/C ON and gear shift lever in neutral position): Standard 700 — 850±100 rpm

ME(H4DOTC)-22

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Ignition Timing MECHANICAL

4. Ignition Timing A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself at measurement.

1. METHOD WITH SUBARU SELECT MONITOR 1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the ignition timing using Subaru Select Monitor. NOTE: If ignition timing is out of standard, check the ignition control system. Refer to “Engine Control System”.

Ignition timing [BTDC/rpm]: Standard 15°±10°/700

2. METHOD WITH TIMING LIGHT 1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Stop the engine, and turn the ignition switch to OFF. 4) Remove the collector cover. 5) Disconnect the ground cable from battery.

6) Remove the air intake duct. 7) Remove the air cleaner case. 8) Connect the timing light to the power wire of #1 ignition coil. 9) Install the air cleaner case. 10) Connect the ground cable to battery.

IG-02107

11) Start the engine, turn the timing light to the crank pulley, and check the ignition timing through the timing belt cover gauge. NOTE: If ignition timing is out of standard, check the ignition control system. Refer to “Engine Control System”.

Ignition timing [BTDC/rpm]: Standard 15°±10°/700 12) After inspection, install the related parts in the reverse order of removal.

IG-02107

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Intake Manifold Vacuum MECHANICAL

5. Intake Manifold Vacuum A: INSPECTION 1) Warm up the engine. 2) Remove the collector cover. 3) Remove the intercooler. 4) Disconnect the brake booster vacuum hose from the intake manifold, and attach the vacuum gauge.

ME-04362

5) Install the intercooler. 6) Keep the engine at idle speed and read the vacuum gauge indication. NOTE: Condition of engine inside can be diagnosed by observing the behavior of the vacuum gauge needle as described in table below.

Intake manifold vacuum (at idling, A/C OFF): Standard –66.7 kPa (–500 mmHg, –19.70 inHg) or more 7) After inspection, install the related parts in the reverse order of removal. Diagnosis of engine condition by inspection of intake manifold vacuum Vacuum gauge needle behavior Possible engine condition 1. Needle is steady but lower than standard value. This tenLeakage around intake manifold gasket, or disconnected or dency becomes more evident as engine temperature rises. damaged vacuum hose 2. Needle intermittently drops to position lower than standard Leakage around cylinder value. 3. Needle drops suddenly and intermittently from standard Sticky valve value. 4. When engine speed is gradually increased, needle begins to Weak or broken valve springs vibrate rapidly at certain speed, and then vibration increases as engine speed increases. 5. Needle vibrates above and below standard value in narrow Defective ignition system range.

ME(H4DOTC)-24

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Engine Oil Pressure MECHANICAL

6. Engine Oil Pressure A: INSPECTION 1) Remove the collector cover. 2) Disconnect the ground cable from battery.

Engine oil pressure: Standard 98 kPa (1.0 kgf/cm2, 14 psi) or more (at 600 rpm) 392 kPa (4.0 kgf/cm2, 57 psi) or more (at 6,000 rpm) 7) After inspection, install the related parts in the reverse order of removal.

IG-02107

3) Remove the oil pressure switch. 4) Attach the oil pressure gauge to the cylinder block.

ME-04363

5) Connect the ground cable to battery.

IG-02107

6) Start the engine, and measure the oil pressure. NOTE: • Standard value is based on an engine oil temperature of 80°C (176°F). • If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. • If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch.

ME(H4DOTC)-25

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Fuel Pressure MECHANICAL

7. Fuel Pressure A: INSPECTION CAUTION: • Before removing the fuel pressure gauge, release the fuel pressure. • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. 1) Remove the collector cover. 2) Release the fuel pressure. 3) Open the fuel filler lid and remove the fuel filler cap. 4) Disconnect the fuel delivery hose from the fuel damper, and connect the fuel pressure gauge.

Fuel pressure: Standard 274 — 304 kPa (2.8 — 3.1 kgf/cm2, 40 — 44 psi) 8) After inspection, install the related parts in the reverse order of removal.

ME-04364

5) Start the engine. 6) Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. NOTE: • The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. • If the fuel pressure is out of specification, check or replace the fuel pump, fuel line, pressure regulator and pressure regulator vacuum hose.

Fuel pressure: Standard 328 — 358 kPa (3.3 — 3.7 kgf/cm2, 48 — 52 psi) 7) After connecting the vacuum hose to the pressure regulator, measure the fuel pressure again. NOTE: • The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations. • If the fuel pressure is out of specification, check or replace the fuel pump, fuel line, pressure regulator and pressure regulator vacuum hose.

ME(H4DOTC)-26

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Valve Clearance MECHANICAL

8. Valve Clearance A: INSPECTION 1) Remove the collector cover. 2) Disconnect the ground cable from battery.

NOTE: Pinch the clamp of the PCV hose by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp. ST 18353AA000 CLAMP PLIERS ST

ME-04374

IG-02107

3) Remove the engine from vehicle. 4) When inspecting #1 and #3 cylinders (1) Remove the timing belt cover RH. (2) Disconnect the connectors from exhaust oil flow control solenoid valve RH (A) and exhaust camshaft position sensor RH (B). ME-04484

(6) Remove the rocker cover RH. 5) When inspecting #2 and #4 cylinders (1) Remove the timing belt cover LH. (2) Disconnect the connectors from exhaust oil flow control solenoid valve LH (A) and exhaust camshaft position sensor LH (B).

(A) (B)

ME-04490

(A)

(3) Remove the clip which holds the engine harness to the rocker cover.

(B)

ME-04491

(3) Disconnect the oil level switch connector.

ME-04332

(4) Remove the ignition coil. (5) Disconnect PCV hose and vacuum hose from the rocker cover RH.

ME-04389

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Valve Clearance MECHANICAL

(4) Remove the clip (A) and bolt (B) securing the engine harness or oil level switch harness to the rocker cover LH.

• Measuring the clearance of #1 cylinder of intake valve and #3 cylinder of exhaust valve

(A) (B)

ME-04090

ME-04485

(5) Remove the ignition coil. (6) Disconnect PCV hose and vacuum hose from the rocker cover LH.

• Measuring the clearance of #2 cylinder of exhaust valve and #3 cylinder of intake valve

NOTE: Pinch the clamp of the PCV hose by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp. ST 18353AA000 CLAMP PLIERS ME-03121 ST

• Measuring the clearance of #2 cylinder of intake valve and #4 cylinder of exhaust valve

ME-04374

ME-03122

• Measuring the clearance of #1 cylinder of exhaust valve and #4 cylinder of intake valve

ME-04486

(7) Remove the rocker cover LH. 6) Turn the crank pulley clockwise until the round mark on the cam sprocket are set to position shown in the figure. NOTE: Turn the crank pulley using a socket wrench.

ME-03123

7) Measure the clearance of intake valve and exhaust valve using thickness gauge (A). NOTE: • Insert a thickness gauge in a direction as horizontal as possible with respect to the valve lifter.

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Valve Clearance MECHANICAL

• Lift up the vehicle, and then measure the exhaust valve clearances. • If the measured value is not within the inspection value, take notes of the value in order to adjust the valve clearance later on.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

Valve clearance (inspection value): Intake 0.20+0.04 –0.06 mm (0.0079+0.0016 –0.0024 in) Exhaust 0.35±0.05 mm (0.0138±0.0020 in) ME-04487

B: ADJUSTMENT

(A)

1) Measure all the valve clearances.

ME-00019

NOTE: Record the measured value of each valve clearance.

8) If necessary, adjust the valve clearance. 9) After inspection, install the related parts in the reverse order of removal. NOTE: • Refer to “Camshaft” when installing the rocker cover. • Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS

ME-00024

2) Remove the camshaft. 3) Remove the valve lifter. 4) Measure the thickness of valve lifter using micrometer.

ST

ME-04374 ME-00025

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Valve Clearance MECHANICAL

5) Select a valve lifter of suitable thickness using the measured valve clearance and valve lifter thickness, and install it.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

NOTE: Use a new valve lifter. Unit: mm (in) Intake valve: S = (V + T) – 0.19 (0.0075) Exhaust valve: S = (V + T) – 0.35 (0.0138) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used ME-04487

6) Install the camshaft. 7) Install the cam sprocket. 8) Install the timing belt. 9) Measure all valves for valve clearance again at this time. If the valve clearance is not within the adjustment value, repeat the procedure over again from the first step.

Valve clearance (adjustment value): Intake 0.20+0.01 –0.03 mm (0.0079+0.0004 –0.0012 in) Exhaust 0.35±0.02 mm (0.0138±0.0008 in) 10) After adjustment, install the related parts in the reverse order of removal. NOTE: • Refer to “Camshaft” when installing the rocker cover. • Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS ST

ME-04374

ME(H4DOTC)-30

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Engine Assembly MECHANICAL

9. Engine Assembly

13) Disconnect the bulkhead harness connector from the engine harness connector (brown).

A: REMOVAL 1) Change the front hood damper mounting position from (A) to (B), and completely open the front hood.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(A) ME-04376

(B)

(B)

14) Remove the bolt securing the bulkhead harness connector bracket, and disconnect the bulkhead harness connector from the engine harness connector (black).

ME-04375

2) Remove the collector cover. 3) Collect the refrigerant from A/C system. 4) Release the fuel pressure. 5) Disconnect the ground cable from battery. ME-04377

15) Disconnect the connector (A) and connector (B) from A/C compressor, and remove the clip (C) securing the generator cord to the intake manifold protector LH. (A)

(C) IG-02107

6) Open the fuel filler lid and remove the fuel filler cap. 7) Remove the air intake duct. 8) Remove the intercooler. 9) Remove the air by-pass valve. 10) Remove the radiator. 11) Remove the front exhaust pipe. 12) Lower the vehicle.

(B) ME-04379

16) Disconnect the following hoses. (1) A/C pressure hose

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Engine Assembly MECHANICAL

19) Disconnect the ground cable on the engine side, and remove the engine harness cover.

(2) Brake booster vacuum hose

ME-04380

(3) Heater inlet hose and heater outlet hose

ME-04242

17) Lift up the vehicle. 18) Remove the intake duct from the air intake boot.

ME-04243

20) Lower the vehicle. 21) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth.

ME-04437

(A)

ST

(B)

(C)

ME-04382

(A) Fuel delivery hose (B) Fuel return hose (C) Evaporation hose

22) Disconnect the fuel return hose using the ST. ST 18371AA000 CONNECTOR REMOVER CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth.

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Engine Assembly MECHANICAL

(1) Attach ST to the fuel return pipe as shown in the figure.

24) Support the engine with a lifting device and wire ropes.

ST FU-03092

(2) Insert the front side of ST into the quick connector.

LU-00222

25) Remove the stopper rod.

ST ME-04381 FU-03113

(3) Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.

26) Remove the bolt and nut which secure engine mounting to the cradle.

ME-04246

ST

27) Lift up the vehicle. FU-03114

23) Remove the clip and disconnect the evaporation hose from the fuel pipe.

CAUTION: When lifting up the vehicle, raise up wire ropes at the same time. 28) Remove the bolts which secure the engine mounting onto the engine, and remove the engine mounting.

FU-04611

ME-04247

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Engine Assembly MECHANICAL

29) Remove the bolts and nuts which hold the lower side of transmission to the engine.

33) Remove the engine from vehicle. (1) Slightly raise the engine. (2) Adjust the height of the transmission with garage jack. (3) Move the engine horizontally until main shaft is withdrawn from clutch cover. (4) Move the engine from engine compartment slowly. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

MT-00077

30) Lower the vehicle. CAUTION: When lifting down the vehicle, lower wire ropes at the same time. 31) Support the transmission with a garage jack. NOTE: Fine adjustment of the transmission height can be performed with this operation.

(A)

B: INSTALLATION 1) Apply a small amount of grease to splines of main shaft.

Grease: NICHIMOLY N-130 or equivalent 2) Position the engine in engine compartment and align it with transmission. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc. 3) Tighten the bolts which hold upper side of transmission to engine.

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

(B)

ME-00215

(A) TRANSMISSION (B) Garage jack

32) Separation of engine and transmission CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked. (1) Remove the starter. (2) Remove the bolts which hold the upper side of the transmission to the engine.

MT-01524

4) Remove the garage jack. 5) Install the starter. 6) Lift up the vehicle. CAUTION: When lifting up the vehicle, raise up wire ropes at the same time. 7) Attach the bolts and nuts which hold lower side of the transmission to engine.

MT-01524

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Engine Assembly MECHANICAL

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb)

MT-00077

8) Set the engine mounting, and tighten the bolts which hold engine mounting to the engine.

ME-04381

12) Remove the lifting device and wire ropes.

Tightening torque: 58 N·m (5.9 kgf-m, 42.8 ft-lb)

LU-00222

13) Lift up the vehicle. 14) Install the intake duct to the air intake boot. ME-04247

9) Lower the vehicle. CAUTION: When lifting down the vehicle, lower wire ropes at the same time. 10) Attach the bolts and nuts which secure engine mounting to the cradle.

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb)

ME-04437

15) Install the engine harness cover, and connect the ground cable.

ME-04246

11) Install the stopper rod.

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Engine Assembly MECHANICAL

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 7 N·m (0.7 kgf-m, 5.2 ft-lb)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

T1

T2 ME-04377

T1

20) Connect the bulkhead harness connector to the engine harness connector (brown).

T2

ME-04248

16) Lower the vehicle. 17) Connect the following hoses. (1) Fuel delivery hose, fuel return hose and evaporation hose (2) Heater inlet hose and heater outlet hose (3) Brake booster vacuum hose (4) A/C pressure hose 18) Install the clip (C) securing the generator cord to the intake manifold protector LH, and connect the connector (A) and connector (B) to the A/C compressor. (A)

ME-04376

21) Install the front exhaust pipe. 22) Install the radiator. 23) Install the air by-pass valve. 24) Install the intercooler. 25) Install the air intake duct. 26) Connect the ground cable to battery.

(C)

(B) ME-04379

19) Connect the bulkhead harness connector to the engine harness connector (black), and install the bolt securing the bulkhead harness connector bracket.

IG-02107

27) Fill engine coolant. 28) Charge the A/C system with refrigerant.

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Engine Assembly MECHANICAL

29) Install the collector cover. 30) Change the front hood damper mounting position from (B) to (A), and close the front hood.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(B)

(A)

(B)

ME-04375

C: INSPECTION 1) Check that the pipes, hoses, connectors and clamps are securely connected. 2) Check that the engine coolant is up to specified level. 3) Start the engine and check for exhaust gas leakage, engine coolant leakage, fuel leakage, noise or vibration.

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Engine Mounting MECHANICAL

10.Engine Mounting

10) Support the engine with a lifting device and wire ropes.

A: REMOVAL 1) Change the front hood damper mounting position from (A) to (B), and completely open the front hood.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(A) LU-00222

(B)

(B)

11) Remove the stopper rod.

ME-04375

2) Remove the collector cover. 3) Disconnect the ground cable from battery. ME-04422

12) Remove the bolt and nut which secure engine mounting to the cradle.

IG-02107

4) Remove the intercooler. 5) Remove the radiator main fan motor assembly and radiator sub fan motor assembly. 6) Lift up the vehicle. 7) Remove the under cover. 8) Remove the front exhaust pipe. 9) Lower the vehicle.

ME-04249

13) Lift up the vehicle. CAUTION: When lifting up the vehicle, raise up wire ropes at the same time. 14) Remove the bolts which secure the engine mounting onto the engine, and remove the engine mounting.

ME-04247

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Engine Mounting MECHANICAL

B: INSTALLATION

5) Remove the lifting device and wire ropes.

1) Set the engine mounting, and tighten the bolts which hold engine mounting to the engine.

Tightening torque: 58 N·m (5.9 kgf-m, 42.8 ft-lb)

LU-00222

ME-04247

2) Lower the vehicle. CAUTION: When lifting down the vehicle, lower wire ropes at the same time. 3) Attach the bolts and nuts which secure engine mounting to the cradle.

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb)

6) Lift up the vehicle. 7) Install the front exhaust pipe. 8) Install the under cover. 9) Lower the vehicle. 10) Install the radiator main fan motor assembly and radiator sub fan motor assembly. 11) Install the intercooler. 12) Connect the ground cable to battery.

ME-04249

4) Install the stopper rod. IG-02107

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb)

13) Install the collector cover. 14) Change the front hood damper mounting position from (B) to (A), and close the front hood.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(B)

(A)

(B)

ME-04422

ME-04375

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Engine Mounting MECHANICAL

C: DISASSEMBLY 1) Remove the turbocharger upper stay from the engine mounting bracket.

2) Install the front cushion rubber to the engine mounting bracket.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

ME-04250

2) Remove the front cushion rubber from the engine mounting bracket.

ME-04251

3) Install the turbocharger upper stay to the engine mounting bracket.

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

ME-04251

3) Remove the front cushion rubber from the front mounting bracket. ME-04250

E: INSPECTION Check that the engine mounting does not have deformation, cracks and any other damage.

ME-04252

D: ASSEMBLY 1) Install the front cushion rubber to the front mounting bracket.

Tightening torque: 45 N·m (4.6 kgf-m, 33.2 ft-lb)

ME-04252

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Preparation for Overhaul MECHANICAL

11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from vehicle body, attach the ST to the engine as shown in the figure. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817100 ENGINE STAND

ST2 ST1 ST3

ME-00057

2) In this section the procedures described under each index are all connected and stated in order. Engine overhaul will be completed when you go through all steps in the procedure. Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.

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V-belt MECHANICAL

12.V-belt

3) Remove the bolt securing the idler pulley to the A/C compressor bracket, and remove the idler pulley.

A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to vehicle body.

1. V-BELT 1) Remove the collector cover. 2) Remove the air intake duct. 3) Attach the tool to the V-belt tensioner assembly, and rotate the tool clockwise to loosen and remove the V-belt.

ME-04385

B: INSTALLATION 1. V-BELT Install in the reverse order of removal. CAUTION: • When reusing the V-belt, wipe off dust and water with cloth. • Do not use the V-belt if there is any oil, grease or coolant on the belt. • Be careful not to rub the V-belt end surface with bare hands; exposed core may cause injury. • Wipe off any dust, oil and water on the groove of each pulley with cloth. (E)

(F)

(G) (D)

(B) (A)

ME-04383 (C)

2. V-BELT TENSIONER ASSEMBLY AND IDLER PULLEY 1) Remove the V-belts. 2) Remove the bolt securing the V-belt tensioner assembly to the power steering pump bracket, and remove the V-belt tensioner assembly.

ME-04386

(A) V-belt (B) V-belt tensioner ASSY (C) (D) (E) (F) (G)

ME-04384

ME(H4DOTC)-42

Crank pulley Idler pulley Generator pulley Power steering pump pulley A/C compressor pulley

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V-belt MECHANICAL

2. V-BELT TENSIONER ASSEMBLY AND IDLER PULLEY Install in the reverse order of removal.

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

C: INSPECTION 1) Check the V-belt for cracks, tear or wear. 2) Remove the air intake duct. 3) Check that the V-belt tensioner assembly and idler pulley do not have deformation, cracks or other damages. 4) Check the V-belt tension indicator (A) shows within the limit (B).

ME-04385

(B)

(A)

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb)

ME-04384 ME-04387

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Crank Pulley MECHANICAL

13.Crank Pulley

NOTE: Set the socket onto the crank pulley bolt so that reference lines (A) and (B) is visible.

A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to vehicle body. 1) Remove the V-belts. 2) Use the ST to lock the crank pulley, and remove the crank pulley bolt. ST 499977100 CRANK PULLEY WRENCH

(A) (B) (a)

(A) (B) (b)

ST

ST

ME-04524 (A)

3) Remove the crank pulley.

(B)

B: INSTALLATION

ME-04526

1. METHOD WITHOUT ANGLE GAUGE

(a) When using 6-point socket

1) Clean the crankshaft thread using compressed air. 2) Install the crank pulley. 3) Apply engine oil to the crank pulley bolt seat and thread. 4) Tighten the crank pulley bolts. (1) Use the ST to lock the crank pulley, and temporarily tighten the crank pulley bolt. ST 499977100 CRANK PULLEY WRENCH

(b) When using 12-point socket

(3) Draw end line (C) on ST using a marker at the same position as reference line (B) was drawn on the socket in step (2). ST 499977100 CRANK PULLEY WRENCH

(C)

Tightening torque: 47 N·m (4.8 kgf-m, 34.7 ft-lb)

ST (B) ME-04527

(4) Use the ST to lock the crank pulley, and tighten the crank pulley bolt to the angle where reference line (A) and end line (C) are aligned. ST 499977100 CRANK PULLEY WRENCH

ST

ME-04525

(2) Draw reference lines (A) and (B) using a marker to set the socket to the crank pulley bolt as shown in the figure. ST 499977100 CRANK PULLEY WRENCH

NOTE: It should be approx. 60° when reference line (A) and end line (C) are aligned.

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Crank Pulley MECHANICAL

Tightening angle: 60°±5°

Tightening angle: 60°±5°

(C)

ST1 ST ST2 (A)

ME-04528

5) Install the V-belts.

2. METHOD WITH ANGLE GAUGE 1) Clean the crankshaft thread using compressed air. 2) Install the crank pulley. 3) Apply engine oil to the crank pulley bolt seat and thread. 4) Tighten the crank pulley bolts. (1) Remove the radiator main fan motor assembly and radiator sub motor assembly. (2) Use the ST1 to lock the crank pulley, and temporarily tighten the crank pulley bolt. ST1 499977100 CRANK PULLEY WRENCH

ME-04530

(4) Install the radiator main fan motor assembly and radiator sub motor assembly. 5) Install the V-belts.

C: INSPECTION Check that the crank pulley has no deformation, cracks or other damages.

Tightening torque: 47 N·m (4.8 kgf-m, 34.7 ft-lb)

ST1

ME-04529

(3) Set the ST2, use the ST1 to lock the crank pulley, and tighten the crank pulley bolt to the specified angle. ST1 499977100 CRANK PULLEY WRENCH ST2 18854AA000 ANGLE GAUGE NOTE: Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.

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Timing Belt Cover MECHANICAL

14.Timing Belt Cover

(6) Disconnect the connector (A) from power steering pump, and remove the power steering pump together with the power steering pump bracket from engine and rod stopper.

A: REMOVAL 1. WORK ON THE VEHICLE 1) Remove the collector cover. 2) Disconnect the ground cable from battery.

(A)

IN-02741

IG-02107

3) When removing the timing belt cover RH (1) Remove the air intake duct. (2) Loosen the clamp which holds the intake duct to intercooler.

(7) Mount the power steering pump together with the power steering pump bracket on RH side wheel apron. (8) Remove the radiator sub fan motor assembly. (9) Remove the engine coolant hose from the clip (A). (10) Remove the bolts which secure the intake duct to the turbocharger, and remove the air bypass valve from the intake duct. (A)

ME-04365

(3) Remove the V-belts.

(4) Remove the generator. (5) Remove the suction hose from intake duct.

IN-02696

(11) Remove the intake duct from intake manifold.

IN-02740

ME(H4DOTC)-46

IN-02698

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Timing Belt Cover MECHANICAL

(12) Disconnect the vacuum hose from blow-by pipe, and remove the bolt securing the blow-by pipe from the intake manifold protector RH.

(19) Remove the clip holding the engine harness.

ME-04488 ME-04366

(13) Disconnect the vacuum hose from PCV pipe.

(20) Loosen the remaining bolts which secure timing belt cover RH, and remove the timing belt cover RH together with the hose clip stay assembly. 4) When removing the timing belt cover LH (1) Disconnect the connectors from front oxygen (A/F) sensor and rear oxygen sensor, and remove the clip (A) securing the front oxygen (A/F) sensor harness and rear oxygen sensor harness.

ME-04367

(14) Remove the vacuum hose (A), vacuum hose (B), vacuum hose (C) and vacuum hose (D) from the clip (E). (A)

(C)

(A)

(D)

(B) (E)

ME-04368

(15) Remove the bolts which secure the upper side of the timing belt cover RH. (16) Lift up the vehicle. (17) Remove the under cover. (18) Remove the air by-pass valve.

EX-02575

(2) Remove the bolts which secure the upper side of the timing belt cover LH. (3) Lift up the vehicle. (4) Remove the under cover. (5) Loosen the remaining bolts which secure timing belt cover LH, and remove the timing belt cover LH together with the oxygen sensor bracket. 5) When removing the front timing belt cover (1) Remove the stopper rod.

ME-04381

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Timing Belt Cover MECHANICAL

(2) Remove the crank pulley. (3) Remove the timing belt cover RH and timing belt cover LH. Refer to step 3) and step 4) for removal procedures. (4) Remove the bolts securing the front timing belt cover, and remove the front timing belt cover.

4) Remove the clip which holds the engine harness to the hose clip stay assembly.

(E) (A) ME-04353

(D) (B) (C)

ME-04306

(A) (B) (C) (D) (E)

Hose clip stay ASSY Timing belt cover RH Oxygen sensor bracket Timing belt cover LH Front timing belt cover

5) Remove timing belt cover RH (B) together with the hose clip stay assembly (A). 6) Remove timing belt cover (LH) (D) together with the oxygen (A/F) sensor bracket (C). 7) Remove front timing belt cover (E).

(E) (A) (D) (B)

2. WORK ON THE ENGINE UNIT ONLY 1) Remove the crank pulley. 2) Remove the blow-by pipe from the intake manifold protector RH.

ME-04438

3) Remove the vacuum hose (A), vacuum hose (B), vacuum hose (C) and vacuum hose (D) from the clip (E). (C)

(A)

(D)

(B) (E)

ME-04439

ME(H4DOTC)-48

(C)

ME-04306

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Timing Belt Cover MECHANICAL

B: INSTALLATION

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

1. WORK ON THE VEHICLE Install in the reverse order of removal. NOTE: Install the vacuum hose as shown in the figure. (b)

(a)

(c) (j)

(k) C

A

D

A B

H

E F

B G E F

(e) I

I

ME-04373

Tightening torque: T1: 3 N·m (0.3 kgf-m, 2.2 ft-lb) T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb) C D

G H

(f)

(h)

(j)

K

J

K

(g)

J

(k)

T1 T2

(i)

ME-04427 (d) ME-04370

(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k)

Blow-by pipe PCV pipe Hose clip stay ASSY Intake duct Vacuum hose (A) Vacuum hose (B) Vacuum hose (C) Vacuum hose (D) To Oil catch tank Clamp Clamp

Tightening torque: Refer to “COMPONENT” of “STARTING/ CHARGING SYSTEMS” for the tightening torque.

(A)

IN-02741

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

Tightening torque: 3 N·m (0.3 kgf-m, 2.2 ft-lb)

ME-04489

ME-04365

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Timing Belt Cover MECHANICAL

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb)

ME-04489

ME-04381

2. WORK ON THE ENGINE UNIT ONLY Install in the reverse order of removal.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

NOTE: Install the vacuum hose as shown in the figure. (b)

(a)

(c) (j)

(k) C

D

A B G

E F

H

E F

(e) I

I

ME-04438

A B

C: INSPECTION C D

Check that the timing belt cover does not have deformation, cracks and any other damage.

G H

(f)

(h)

(j)

K J

J

K

(g) (k)

(i)

(d) ME-04370

(a) (b) (c) (d) (e)

Blow-by pipe PCV pipe Hose clip stay ASSY Intake duct Vacuum hose (A)

(f) (g) (h) (i) (j) (k)

Vacuum hose (B) Vacuum hose (C) Vacuum hose (D) To Oil catch tank Clamp Clamp

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Timing Belt MECHANICAL

15.Timing Belt A: REMOVAL NOTE: • When replacing the single part, perform the work with the engine installed to vehicle body. • When performing the work with the engine installed to body, the following parts must also be removed/installed. • Radiator main fan motor assembly • Radiator sub fan motor assembly • When performing the work with the engine installed to body, protect the radiator with cardboards or blankets.

1. TIMING BELT 1) Remove the crank pulley. 2) Remove the timing belt cover. 3) Remove the timing belt guide.

ME-04307

ME-03126

4) If the alignment mark or arrow mark (which indicates the direction of rotation) on timing belt fade away, put new marks before removing the timing belt as shown in procedures below. (1) Turn the crankshaft using ST, and align the alignment marks on crank sprocket, intake cam sprocket LH, exhaust cam sprocket LH, intake cam sprocket RH and exhaust cam sprocket RH with marks on oil pump and notches of timing belt cover. ST 499987500 CRANKSHAFT SOCKET

ME-00230

ST ME-00231

ME-03124

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Timing Belt MECHANICAL

(2) Using white paint, put an alignment mark or an arrow mark on timing belts in relation to the crank sprocket and cam sprockets.

CAUTION: After the timing belt has been removed, never rotate the intake and exhaust cam sprocket. If the cam sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent.

2. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER 1) Remove the belt idler (A) and (B). (B) ME-00070

(A) ME-04310

2) Remove the belt idler No. 2. ME-04308

Z1: 54.5 teeth Z2: 51 teeth Z3: 28 teeth

Z3

Z1

Z2

Z3 ME-00075

3) Remove the automatic belt tension adjuster assembly.

ME-03128

5) Remove the belt idler (A).

ME-03130

(A) ME-04309

6) Remove the timing belt.

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Timing Belt MECHANICAL

B: INSTALLATION 1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb)

1) Prepare for installation of the automatic belt tension adjuster assembly. CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down. • Do not use a lateral type vise. • Push the adjuster rod vertically. • Press-in the push adjuster rod gradually taking three minutes or more. • Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbf). • Push in the adjuster rod to the end face of the cylinder. However, do not press the adjuster rod below the end face of the cylinder. Doing so may damage the cylinder. • Do not release the press pressure until stopper pin is completely inserted. (1) Attach the automatic belt tension adjuster assembly to vertical pressing tool. (2) Slowly push in the adjuster rod with a pressure of 165 N (16.8 kgf, 37.1 lbf) or more until the adjuster rod is aligned with the stopper pin hole in the cylinder.

ME-03131

3) Install the belt idler No. 2.

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb)

ME-00075

4) Install the belt idlers.

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb)

ME-00239

(3) With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex wrench inserted into the stopper pin hole in cylinder, secure the adjuster rod.

ME-03449

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

ME-00350

2) Install the automatic belt tension adjuster assembly.

ME(H4DOTC)-53

ME-03567

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Timing Belt MECHANICAL

2. TIMING BELT 1) Prepare for installation of the automatic belt tension adjuster assembly. 2) Align the mark (B) on crank sprocket with the mark (A) on oil pump. (B)

5) Align the single line mark (B) on exhaust cam sprocket LH with notch (A) on the timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine).

(A)

(A)

(B)

ME-04311

ME-04082

3) Align the single line (B) on the exhaust cam sprocket RH with notch (A) of timing belt cover.

6) Align the single line mark (B) on intake cam sprocket LH with notch (A) on the timing belt cover by turning the sprocket clockwise (as viewed from front of engine). Make sure the double line marks (C) on the intake and exhaust cam sprockets are aligned. (A)

(B)

(A)

(B)

(C)

ME-04086

ME-04083

4) Align the single line (B) on the intake cam sprocket RH with notch (A) of timing belt cover. Make sure that the double line marks (C) on intake and exhaust cam sprockets are aligned.

7) Make sure that the cam and crank sprockets are positioned properly.

(A) (B)

(C)

ME-04084

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Timing Belt MECHANICAL

CAUTION: • Intake and exhaust camshafts for this DOHC engine can be independently rotated with the timing belts removed. As can be seen from the figure, if the intake and exhaust valves are lifted simultaneously, heads will interfere with each other, resulting in bent valves. (A)

• Do not allow the camshafts to rotate in the direction shown in the upper figure. Doing this may cause both the intake and exhaust valves to lift simultaneously, resulting in mutual interference of valve heads. (A)

NG N G OK OK (A)

(B)

(A)

(B)

(A)

ME-03136

(B) ME-04111

(A) Direction of rotation (B) Timing belt installation position

(A) Intake camshaft (B) Exhaust camshaft

• When the timing belts are not installed, four camshafts are held at the “zero-lift” position, where all cams on camshafts are not pushing down on the intake and exhaust valves. (Under this condition, all valves remain unlifted.) • When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of camshaft LH are held, pushing their corresponding valves down. (Under this condition, these valves are held lifted.) Camshaft RH are held so that their cams do not push the valves down. • Camshafts LH must be rotated from the zerolift position to the position where the timing belt is to be installed with the smallest possible angle, in order to prevent mutual interference of intake and exhaust valve heads.

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Timing Belt MECHANICAL

8) Align the alignment mark on the timing belt with marks on the sprockets in the alphabetical order shown in the figure. While aligning marks, position the timing belt properly, and install the timing belt. CAUTION: • If the timing belt slips by 1 or more teeth, the valve and piston may hit each other. • Make sure that the direction of belt rotation is correct. (1)

(2)

(4)

(3)

(5)

(D)

(6) (B)

(A) RH-IN

LH-IN

RH-EX

LH-EX

(E)

(1) (2) (3)

Arrow mark Timing belt 28 teeth

(7)

(4) (5) (6)

(C)

54.5 teeth 51 teeth 28 teeth

(7)

ME-03137

Install it in the end

10) After ensuring that the marks on the timing belt and sprockets are aligned, remove the stopper pin from tensioner adjuster.

9) Install the belt idlers.

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb) NOTE: Make sure that the marks on the timing belt and sprockets are aligned.

ME-00245

ME-00090

11) Install the timing belt guide. (1) Temporarily tighten the bolts mounting the timing belt guide. NOTE: • Before installing the timing belt guide, clean the timing belt guide mounting bolt holes of the timing belt cover No. 2. • Apply liquid gasket to the thread of the timing belt guide mounting bolt on the cam sprocket section. (when reusing bolts)

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Timing Belt MECHANICAL

Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent

(2) Adjust the clearance between timing belt and timing belt guide using a thickness gauge and tighten.

Clearance: 1.0±0.5 mm (0.039±0.020 in)

ME-00230

ME-00246

ME-03124

ME-03138

ME-04307

ME-04312

ME-03126

ME-03140

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Timing Belt MECHANICAL

C: INSPECTION

Tightening torque: 9.75 N·m (1.0 kgf-m, 7.2 ft-lb)

1. TIMING BELT 1) Check the timing belt teeth for breaks, cracks or wear. If any fault is found, replace the timing belt. 2) Check the condition on the back surface of the timing belt. If cracks are found, replace the timing belt.

ME-00247

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

CAUTION: • Be careful not to let oil, grease or coolant contact the timing belt. Remove quickly and thoroughly if this happens. • Do not bend the timing belt sharply.

In radial diameter h: 60 mm (2.36 in) or more

h

ME-03124 ME-00248

2. AUTOMATIC BELT TENSION ADJUSTER 1) Visually check the oil seals for leaks, and rod ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster assembly.

ME-04307

ME-03126

12) Install the timing belt cover. 13) Install the crank pulley.

NOTE: Slight traces of oil on the oil seal of the rod does not indicate a problem. 2) Check that the adjuster rod does not move when a pressure of 165 N (16.8 kgf, 37.1 lbf) is applied to it. This is to check adjuster rod stiffness. 3) If the adjuster rod is not stiff enough and moves freely when applying 165 N (16.8 kgf, 37.1 lbf), check it using the following procedures: (1) Slowly press the adjuster rod down to the end surface of cylinder. Repeat this operation two to three times. (2) With the adjuster rod moved all the way up, apply a pressure of 165 N (16.8 kgf, 37.1 lbf) to it, and check the adjuster rod stiffness. (3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new part. CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down. • Do not use a lateral type vise.

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Timing Belt MECHANICAL

• Push the adjuster rod vertically. • Press-in the push adjuster rod gradually taking three minutes or more. • Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lbf). • Push in the adjuster rod to the end face of the cylinder. However, do not press the adjuster rod below the end face of the cylinder. Doing so may damage the cylinder. 4) Measure the amount of adjuster rod protrusion “L” from the end surface of the cylinder. If it is not within specifications, replace the automatic belt tension adjuster assembly with a new part.

Protrusion amount of adjuster rod L: 5.2 — 6.2 mm (0.205 — 0.244 in)

L

ME-04106

3. BELT TENSION PULLEY 1) Check the mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace the automatic belt tension adjuster assembly with a new part if faulty. 2) Check the belt tension pulley for smooth rotation. Replace the automatic belt tension adjuster assembly with a new part if abnormal noise or excessive play occurs. 3) Check the belt tension pulley for grease leakage.

4. BELT IDLER 1) Check the belt idler for smooth rotation. Replace if noise or excessive play occurs. 2) Check the outer contacting surfaces of idler pulley for abnormal wear and scratches. 3) Check the belt idler for grease leakage.

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Cam Sprocket MECHANICAL

16.Cam Sprocket

NOTE: Use new O-rings.

A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to vehicle body. 1) Remove the crank pulley. 2) Remove the timing belt cover. 3) Remove the timing belt. 4) Remove the actuator covers of intake cam sprocket and exhaust cam sprocket. 5) Use the ST to lock the cam sprocket, and remove the cam sprocket bolt. ST 499977500 CAM SPROCKET WRENCH

Tightening torque: 3.4 N·m (0.3 kgf-m, 2.5 ft-lb) 4) Install the timing belt. 5) Install the timing belt cover. 6) Install the crank pulley.

C: INSPECTION 1) Check the cam sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between cam sprocket and key.

ST ME-04313

6) Remove the cam sprocket.

B: INSTALLATION 1) Install the cam sprocket. 2) Use the ST to lock the cam sprocket, and install the cam sprocket bolt. NOTE: Do not confuse cam sprockets (LH) and (RH) or (INT) and (EXH) during installation. ST 499977500 CAM SPROCKET WRENCH

Tightening torque: Tighten to 30 N·m (3.1 kgf-m, 22.1 ft-lb) of torque, and then tighten further by 45°.

ST ME-04313

3) Install the actuator covers of intake cam sprocket and exhaust cam sprocket.

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Crank Sprocket MECHANICAL

17.Crank Sprocket A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to vehicle body. 1) Remove the crank pulley. 2) Remove the timing belt cover. 3) Remove the timing belt. 4) Remove the crank sprocket.

ME-00103

B: INSTALLATION 1) Install the crank sprocket.

ME-00103

2) Install the timing belt. 3) Install the timing belt cover. 4) Install the crank pulley.

C: INSPECTION 1) Check the crank sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between crank sprocket and key. 3) Check the crank sprocket protrusion used for sensor for damage and contamination of foreign matter.

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Camshaft MECHANICAL

18.Camshaft

6) Disconnect connectors from exhaust camshaft position sensor (A) and exhaust oil flow control solenoid valve (B).

A: REMOVAL 1) Remove the crank pulley. 2) Remove the timing belt cover. 3) Remove the timing belt. 4) Remove the cam sprocket. 5) Disconnect connectors of the intake oil flow control solenoid valve.

(A) (B)

(A)

(B) ME-04492

7) Remove the timing belt cover No. 2 (RH) (A) and timing belt cover No. 2 LH (B). NOTE: Do not damage or lose the seal rubber when removing the timing belt covers. (A) (B) ME-04388

ME-04316

8) Remove the tensioner bracket.

ME-00105

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Camshaft MECHANICAL

9) Disconnect the oil level switch connector.

NOTE: Pinch the clamp of the PCV hose by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure, and unlock the clamp. ST 18353AA000 CLAMP PLIERS ST

ME-04389

10) Remove the clip (A) and bolt (B) securing the engine harness or oil level switch harness to the rocker cover. ME-04374

(A)

(A) (B)

ME-04390

11) Remove the ignition coil. 12) Remove the scavenge pump. (RH side only)

13) Disconnect PCV hose and vacuum hose from the rocker cover.

ME-04440

14) Remove the rocker cover.

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Camshaft MECHANICAL

15) Remove the union bolt without filter (without protrusion) which secures the oil pipe to the front camshaft cap. (A)

(B)

(C)

(D)

(D)

16) Loosen the bolts located on the upper side of the front camshaft cap, intake camshaft cap and rear camshaft cap (RH side only) equally, a little at a time in alphabetical order, as shown in the figure. (G)

(D)

(H)

(E)

(D)

(F)

(A)

(B) (C)

(C)

(A)

(B)

(E)

(C)

(F)

(D)

(D)

(B) (A) (D) ME-04320

ME-04317

(A) (B) (C) (D)

Union bolt with filter (with protrusion) Union bolt without filter (without protrusion) Oil pipe Gasket

17) Loosen the lower side of the front camshaft cap and the exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.

(A)

(B)

(C)

(E)

(D)

(F)

(A)

(B)

(E)

(C)

(F)

(D)

ME-04349

18) Remove the front camshaft cap. 19) Remove the intake camshaft caps, intake camshaft and rear camshaft caps (RH side only).

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Camshaft MECHANICAL

20) Remove the exhaust camshaft caps and exhaust camshaft.

Exhaust camshaft LH: Rotate 45° counterclockwise.

NOTE: Arrange camshaft caps in order so that they can be installed in their original positions. 21) Remove the oil seal.

A (a)

77.5

(b) 11

CAUTION: Do not scratch the journal surface when removing the oil seal. 22) Similarly, remove the camshaft RH and related parts.

B: INSTALLATION 1) Install the camshaft. Apply engine oil to the cylinder head at camshaft journal installation location before installing the camshaft. Install the camshaft so that each valve is close to or in contact with base circle of the cam lobe. NOTE: • Set the camshaft to the position shown in the figure. • When set at the position shown in the figure, it is not necessary to rotate the camshaft RH when installing the timing belt, but it is necessary to rotate the camshaft LH slightly.

Intake camshaft LH: Rotate 80° clockwise.

B (b)

11

77.5 (a)

ME-00111

A B (a) (b)

Cylinder head LH Cylinder head RH Intake camshaft Exhaust camshaft

2) Install the camshaft cap. (1) Apply small amount of liquid gasket to the mating surface of front camshaft cap and rear camshaft cap (RH side only). NOTE: • Install within 5 min. after applying liquid gasket. • Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to come out and flow toward oil seal, resulting in oil leak.

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Camshaft MECHANICAL

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

Tightening torque: T1: 9.75 N·m (1.0 kgf-m, 7.2 ft-lb) T2: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (M)

(G)

(C)

(L)

T1

T1 T2

T1

(K)

(N)

(J)

(E)

(A) T2

(F)

(B)

T1

(D)

(I)

ME-00773 (G)

(H)

(L)

(C)

T1 T2 (E) (F)

(A) (B)

(K) T2

(J)

T1

ME-04318

(2) Apply a thin coat of engine oil to the cap journal surface, and install the camshaft cap to the camshaft. (3) Gradually tighten the camshaft cap in at least two steps, in alphabetical order shown in the figure, and then tighten to the specified torque.

(H)

(D)

(I)

ME-04352

(4) After tightening the camshaft cap, ensure the camshaft rotates only slightly while holding it at base circle. 3) Apply a thin coat of engine oil to the periphery of the camshaft oil seal and oil seal lip, and install the oil seal on the camshaft using ST1 and ST2. NOTE: Use a new oil seal. ST1 499587600 OIL SEAL INSTALLER ST2 499597200 OIL SEAL GUIDE

ST1 ST2

ME-00116

4) Install the oil pipe to the front camshaft cap using the union bolt without filter (without protrusion).

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Camshaft MECHANICAL

Tightening torque: 29 N·m (3.0 kgf-m, 21.4 ft-lb) (A)

(B)

(C)

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

(D)

(D)

(A) (D)

(B)

ME-04316

(B) (C)

(D)

(A) (D) ME-04320

(A) Union bolt with filter (with protrusion) (B) Union bolt without filter (without protrusion) (C) Oil pipe (D) Gasket

7) Install the cam sprocket. 8) Install the timing belt. 9) Adjust the valve clearance. 10) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. (Outer periphery and ignition coil section) NOTE: Use a new rocker cover gasket. (2) Apply liquid gasket to the specified point of the cylinder head. NOTE: Install within 5 min. after applying liquid gasket.

5) Install the tensioner bracket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

Tightening torque: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

ME-00105

6) Install the timing belt cover No. 2 RH (A) and timing belt cover No. 2 LH (B).

ME-04321

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Camshaft MECHANICAL

(3) Install the rocker cover to cylinder head. Ensure the gasket is properly positioned during installation. (4) Temporarily tighten the rocker cover bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order.

NOTE: Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

ST

(C),(K)

(E)

(H)

(B),(J)

(A),(I) ME-04374

(F)

(G)

(D),(L) (C),(K)

(H)

(E)

(B),(J) (A),(I)

(G)

(D),(L)

(F)

ME-04351

11) Install the scavenge pump. 12) Connect the PCV hose and vacuum hose to the rocker cover.

ME-04440

13) Install the ignition coil. 14) Secure the engine harness or oil level switch harness to the rocker cover with the clip (A) and bolt (B).

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Camshaft MECHANICAL

16) Connect the connectors to the intake oil flow control solenoid valve.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(A)

(A) (B)

ME-04388

ME-04390

15) Connect the connector to the oil level switch.

17) Connect the connectors to exhaust camshaft position sensor (A) and exhaust oil flow control solenoid valve (B).

(A) (B)

ME-04389

(A)

(B) ME-04492

18) Install the timing belt cover. 19) Install the crank pulley.

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Camshaft MECHANICAL

C: INSPECTION 1) Measure the bend, and repair or replace if necessary.

Camshaft bend limit: 0.020 mm (0.00079 in)

7) Measure the oil clearance of camshaft journal. (1) Clean the camshaft cap and cylinder head camshaft journal. (2) Place the camshaft on cylinder head. (Without installing the valve lifter) (3) Place a plastigauge across each camshaft journals. (4) Gradually tighten the camshaft cap in at least two steps, in alphabetical order shown in the figure, and then tighten to the specified torque. Do not turn the camshaft.

Tightening torque: T1: 9.75 N·m (1.0 kgf-m, 7.2 ft-lb) T2: 20 N·m (2.0 kgf-m, 14.8 ft-lb) ME-00118

2) Check the journal for damage and wear. Replace if faulty. 3) Check the cutout portion used for camshaft sensor for damage. Replace if faulty. 4) Check the cam face condition, and remove the minor faults by grinding with oil stone. Replace if there is uneven wear or others. 5) Measure the cam lobe height “H” and cam base circle diameter “A”. If it exceeds the standard or offset wear occurs, replace it.

Cam lobe height H:

T1 T2 (K) (J)

(E)

(A) T2

(F)

(B)

T1

(D)

(I)

(G)

(H)

(L)

(C)

T1

Standard Intake 46.55 — 46.65 mm (1.833 — 1.837 in) Exhaust 45.85 — 45.95 mm (1.805 — 1.809 in) Cam base circle diameter A: Standard 37.0 mm (1.457 in)

A

T2 (E) (F)

(A) (B)

(K) T2

(J)

T1

(H)

(D)

(I)

ME-04350

(5) Remove the camshaft cap. (6) Measure the widest point of the plastigauge on each journal. If oil clearance exceeds the standard, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set.

H

ME-00276

6) Measure the outside diameter of camshaft journal. If the journal diameter is not within specification, check the oil clearance.

Standard mm (in)

(G)

(C)

(L)

Camshaft journal Front Center, rear 37.946 — 37.963 29.946 — 29.963 (1.4939 — 1.4946) (1.1790 — 1.1796)

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Camshaft MECHANICAL

Camshaft oil clearance: Standard 0.037 — 0.072 mm (0.0015 — 0.0028 in)

ME-00119

(7) Completely remove the plastigauge. 8) Measure the thrust clearance of camshaft with the dial gauge set at end of camshaft. If the thrust clearance is not within the standard or there is offset wear, replace the camshaft caps and cylinder head as a set. If necessary replace the camshaft.

Camshaft thrust clearance: Standard 0.068 — 0.116 mm (0.0027 — 0.0047 in)

ME-00121

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Cylinder Head MECHANICAL

19.Cylinder Head A: REMOVAL 1) Remove the intake manifold. 2) Remove the crank pulley. 3) Remove the timing belt cover. 4) Remove the timing belt. 5) Remove the cam sprocket. 6) Remove the bolt which holds A/C compressor bracket onto cylinder head. (LH side only) 7) Remove the oil pipe. 8) Remove the clip stay.

NOTE: Leave the bolts (A) and (D) engaged by three or four threads to prevent the cylinder head from falling.

(A)

(F)

(D)

(C)

(E)

(B)

(D)

(F)

(A)

(B)

(E)

(C) ME-04298

ME-04323

12) While tapping the cylinder head with a plastic hammer, separate it from cylinder block. Remove the bolts (A) and (D) to remove cylinder head.

9) Remove the camshaft. 10) Remove the oil level gauge guide. (LH side only) 11) Remove the cylinder head bolts in alphabetical order shown in the figure.

(A)

(F)

(D)

(C)

(E)

(B)

(D)

(F)

(A)

(B)

(E)

(C) ME-04298

13) Remove the cylinder head gasket. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block.

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Cylinder Head MECHANICAL

B: INSTALLATION 1) Install the cylinder head to the cylinder block.

(F)

(A)

(C)

(D)

(B)

(E)

CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. NOTE: Use a new cylinder head gasket. (1) Clean the bolt threads and the bolt holes in the cylinder block. CAUTION: To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc. (2) Apply a sufficient coat of engine oil to the washer and bolt thread. (3) Tighten all bolts to 40 N·m (4.1 kgf-m, 29.5 ft-lb) in alphabetical order. (4) Retighten all bolts to 95 N·m (9.7 kgf-m, 70.1 ft-lb) in alphabetical order. CAUTION: If the bolt makes stick-slip sound during tightening, repeat the procedure from step (1). In this case, the cylinder head gasket can be reused. (5) Loosen all the bolts by 180° in the reverse order of installing, and loosen them further by 180°. (6) Tighten all bolts to 10 N·m (1.0 kgf-m, 7.4 ftlb) in alphabetical order. (7) Retighten all bolts to 30 N·m (3.1 kgf-m, 22.1 ft-lb) in alphabetical order. (8) Retighten all bolts to 70 N·m (7.1 kgf-m, 51.6 ft-lb) in alphabetical order. (9) Retighten all bolts by 80 — 90° in alphabetical order. (10) Retighten all bolts by 40 — 45° in alphabetical order. CAUTION: The tightening angle of the bolt should not exceed 45°. (11) Retighten bolts (A) and (B) by 40 — 45°. CAUTION: Make sure the total “tightening angle” of steps (10) and (11) does not exceed 90°.

(C)

(A)

(F)

(E)

(B)

(D) ME-04319

2) Install the oil level gauge guide. (LH side only)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 3) Install the camshaft. 4) Install the clip stay. Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb)

ME-04323

5) Install the oil pipe. 6) Install the A/C compressor bracket on cylinder head. (LH side only)

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb) 7) Install the cam sprocket. 8) Install the timing belt. 9) Adjust the valve clearance.

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10) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. (Outer periphery and ignition coil section) NOTE: Use a new rocker cover gasket. (2) Apply liquid gasket to the specified point of the cylinder head.

(C),(K)

(E)

(H)

(B),(J)

NOTE: Install within 5 min. after applying liquid gasket.

(A),(I)

(F)

(G)

(D),(L)

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

(C),(K)

(H)

(E)

(B),(J) (A),(I)

(G)

(D),(L)

(F)

ME-04351

11) Connect the PCV hose to the rocker cover. 12) Install the timing belt cover. 13) Install the crank pulley. 14) Install the intake manifold.

ME-04321

(3) Install the rocker cover to cylinder head. Ensure the gasket is properly positioned during installation. (4) Temporarily tighten the rocker cover bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

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C: DISASSEMBLY 1) Remove the valve lifter. 2) Place the cylinder head on ST1. ST1 498267600 CYLINDER HEAD TABLE 3) Using ST2, compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST2 499718000 VALVE SPRING REMOVER NOTE: • Mark each valve to prevent confusion. • Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. • Keep all the removed parts in order for re-installing in their original positions. • For removal and installation procedures of the valve guide, intake valve oil seal and exhaust valve oil seal, refer to “INSPECTION”.

ST2

ST1

ME-03142

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D: ASSEMBLY (1)

(11)

(4)

(5)

(6)

(7)

(8)

(9)

(3)

(2)

(11) (4) (12)

(5)

(6)

(7)

(8)

(9)

(4) (10) (6) (7)

(12)

(8) (9)

(4) (10) (6) (7) (8) (9)

ME-04120

(1) (2) (3) (4)

Exhaust valve Intake valve Cylinder head Valve spring seat

(5) (6) (7) (8)

Intake valve oil seal Valve spring Retainer Retainer key

ME(H4DOTC)-76

(9) (10) (11) (12)

Valve lifter Exhaust valve oil seal Intake valve guide Exhaust valve guide

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1) Install the valve spring and valve. (1) Coat the valve stem of each valve with engine oil and insert the valve into valve guide. NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. (2) Set the cylinder head on ST1. ST1 498267600 CYLINDER HEAD TABLE (3) Install the valve spring and retainer.

NOTE: Uneven torque for the cylinder head bolts can cause warping. When reinstalling, pay special attention to the torque so as to tighten evenly. (A)

NOTE: Be sure to install the valve spring with its closecoiled end facing the cylinder head. (4) Set the ST2 on valve spring. ST2 499718000 VALVE SPRING REMOVER

(B) ME-00126

2. VALVE SEAT Inspect the intake and exhaust valve seats, and correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are replaced.

ST2

Contacting width of valve and valve seat W: ST1

ME-03142

(5) Compress the valve spring and fit the valve spring retainer key. (6) After installing, tap the valve spring retainers lightly with a plastic hammer for better seating. 2) Apply oil to the surface of valve lifter. 3) Install the valve lifter.

Standard Intake 0.6 — 1.4 mm (0.024 — 0.055 in) Exhaust 1.2 — 1.8 mm (0.047 — 0.071 in)

E: INSPECTION

W

1. CYLINDER HEAD 1) Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Measure the warping of the cylinder head surface that mates with cylinder block using a straight edge (A) and thickness gauge (B). If the warping exceeds the limit, correct the surface by grinding it with a surface grinder.

ME-00127

Warping limit: 0.035 mm (0.0014 in) Grinding limit: 0.3 mm (0.012 in) Standard height of cylinder head: 127.5 mm (5.02 in)

ME-00287

3. VALVE GUIDE 1) Check the clearance between valve guide and valve stem. The clearance can be checked by measuring respectively the outer diameter of valve stem with a micrometer and the inner diameter of valve guide with a caliper gauge.

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Clearance between the valve guide and valve stem: Standard Intake 0.030 — 0.057 mm (0.0012 — 0.0022 in) Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in) 2) If the clearance between valve guide and valve stem exceeds the standard, replace the valve guide or valve itself, whichever shows the greater amount of wear or damage. See the following procedure for valve guide replacement.

(5) Coat a new valve guide with sufficient oil, put it into the cylinder head, and insert the ST1 into the valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER ST2 18251AA020 VALVE GUIDE ADJUSTER ST1 ST2

Valve guide inner diameter: 6.000 — 6.012 mm (0.2362 — 0.2367 in) Valve stem outer diameters: Intake 5.955 — 5.970 mm (0.2344 — 0.2350 in) Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in) (1) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides fit the holes in ST1. (2) Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 498267600 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER

ME-00130

(6) Check the valve guide protrusion amount “L”.

Valve guide protrusion amount L: 15.8 — 16.2 mm (0.622 — 0.638 in)

L ST2

ME-04522

ST1 ME-00128

(3) Turn the cylinder head upside down and place the ST as shown in the figure. ST 18251AA020 VALVE GUIDE ADJUSTER

(7) Ream the inside of valve guide using ST. Put the ST in valve guide, and rotate the ST slowly clockwise while pushing it lightly. Bring the ST back while rotating it clockwise. NOTE: • Apply engine oil to the ST when reaming. • If the inner surface of valve guide is damaged, the edge of ST should be slightly ground with oil stone.

ST

ME-04107

(4) Before installing a new valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head.

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• If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or remedy the ST. ST 499767400 VALVE GUIDE REAMER

2) Put a small amount of grinding compound on the valve seat surface, and lap the valve and valve seat surface. Replace with a new valve oil seal after lapping. NOTE: It is possible to differentiate between the intake valve and the exhaust valve by their overall length.

Valve overall length: Intake 104.4 mm (4.110 in) Exhaust 104.65 mm (4.1201 in)

ST

ME-04393

(8) After reaming, clean the valve guide to remove chips. (9) Recheck the contact condition between valve and valve seat after replacing the valve guide.

4. INTAKE AND EXHAUST VALVE 1) Inspect the flange and valve stem of valve, and replace the valve with a new part if damaged, worn, deformed, or if dimension “H” in the figure is outside of the specified limit.

Head edge thickness H: Standard Intake (A) 1.0 — 1.4 mm (0.039 — 0.055 in) Exhaust (B) 1.3 — 1.7 mm (0.051 — 0.067 in)

5. VALVE SPRING 1) Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table. 2) To measure the squareness of the valve spring, stand the valve spring on a surface plate and measure its deflection at the top of valve spring using a right angle gauge. Free length Tension/spring height N (kgf, lbf)/mm (in) Squareness

mm (in) 47.32 (1.863) Set Lift

205 — 235 (20.90 — 23.96, 46.09 — 52.84)/36.0 (1.417) 426 — 490 (43.44 — 49.96, 95.78 — 110.17) /26.5 (1.043) 2.5°, 2.1 mm (0.083 in) or less

(A)

H ME-00283

6. INTAKE AND EXHAUST VALVE OIL SEAL (B)

H

ME-00758

1) For the following, replace the oil seal with a new part. See the procedure 2) and subsequent for replacement procedures. • When the lip is damaged. • When the spring is out of the specified position. • When readjusting the surfaces of valve and valve seat. • When replacing the valve guide. 2) Place the cylinder head on ST1, and use ST2 to press-fit the oil seal. ST1 498267600 CYLINDER HEAD TABLE ST2 498857100 VALVE OIL SEAL GUIDE

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NOTE: • Apply engine oil to oil seal before press-fitting. • When press-fitting the oil seal, do not use a hammer or strike in. • The intake valve oil seals and exhaust valve oil seals are distinguished by their colors.

Color of rubber part: Intake [Gray] Exhaust [Green]

4) Check the clearance between valve lifter and valve lifter mating surface. The clearance can be determined from the measured value of the valve lifter outer diameter and valve lifter mating surface inner diameter. If it is not within the standard or there is uneven wear in the inner surface, replace the cylinder head.

Clearance between valve lifter and valve lifter mating surface: Standard 0.019 — 0.057 mm (0.0007 — 0.0022 in)

ST2

ME-00133

7. VALVE LIFTER 1) Perform visual check on the valve lifter. 2) Measure the valve lifter outer diameter.

Outer diameter of valve lifter: 34.959 — 34.975 mm (1.3763 — 1.3770 in)

ME-00134

3) Measure the inner diameter of valve lifter mating surface on cylinder head.

Inner diameter of valve lifter mating surface: 34.994 — 35.016 mm (1.3777 — 1.3786 in)

ME-00135

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Cylinder Block MECHANICAL

20.Cylinder Block

CAUTION: Be careful not to damage the mating surface of the cylinder block and oil pump.

A: REMOVAL NOTE: Before conducting this procedure, drain the engine oil completely. 1) Remove the intake manifold. 2) Remove the crank pulley. 3) Remove the timing belt cover. 4) Remove the timing belt. 5) Remove the cam sprocket. 6) Remove the crank sprocket. 7) Remove the A/C compressor together with the bracket. 8) Remove the camshaft. 9) Remove the cylinder head. 10) Remove the clutch disc and cover. 11) Remove the flywheel. 12) Remove the oil separator cover. 13) Remove the oil filter. 14) Remove the oil cooler. 15) Remove the water pump. 16) Remove the bolt which secures the oil pump to the cylinder block. NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.

ME-00138

18) Remove the front oil seal from the oil pump. 19) Remove the clip holding the oil level switch harness from cylinder block.

ME-04392

20) Remove the oil pan and cylinder block lower. (1) Set the part so that the cylinder block LH is on the upper side. (2) Remove the bolts which secure the oil pan to the cylinder block lower. (3) Insert an oil pan cutter blade into the gap between cylinder block lower and oil pan, and remove the oil pan. CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter. (4) Remove the bolts which secure the cylinder block lower to the cylinder block, and remove the cylinder block lower by using flat tip screwdriver.

LU-00015

17) Remove the oil pump from cylinder block using a flat tip screwdriver.

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CAUTION: Insert the flat tip screwdriver at the position shown in the figure, and avoid scratching the mating surface of the cylinder block and cylinder block lower.

(A)

(C)

(B) (D)

ME-04426

21) Remove the baffle plate. 22) Remove blow-by pipe assembly (A), blow-by pipe (B), PCV hose assembly (C) and water pipe assembly (D). NOTE: To unlock the clamp of the blow-by pipe assembly (A), blow-by pipe (B) and PCV hose assembly (C), pinch the clamp by fitting the cut out in the ST with the protrusion on the clamp as shown in the figure. ST 18353AA000 CLAMP PLIERS ST

ME-04374

ME(H4DOTC)-82

ME-04394

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23) Remove the water by-pass pipe.

ME-04325

(2)

(1)

(3) (4) (6) (4)

(3)

(5)

(4) (2)

(3)

(1)

(8) (4)

(7)

(3) (1)

(2) ME-02889

(1) (2) (3)

Service hole plug Gasket Snap ring

(4) (5) (6)

Piston pin Service hole cover O-ring

ME(H4DOTC)-83

(7) (8)

Seal washer Washer

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Cylinder Block MECHANICAL

24) Remove the service hole plugs using a hexagon wrench [14 mm].

ME-00140

25) Remove the service hole cover. 26) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove the piston snap ring through service hole of #1 and #2 cylinders.

ME-00141

27) Draw out the piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER ASSY NOTE: Be careful not to confuse the original combination of piston, piston pin and cylinder.

ST

ME-03325

28) Similarly remove the piston pins from #3 and #4 pistons. 29) Remove the cylinder block connecting bolt on the RH side. 30) Loosen the cylinder block connecting bolt on the LH side by 2 to 3 turns. 31) Set the part so that the cylinder block LH is on the upper side, and remove the cylinder block connecting bolt.

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32) Separate cylinder block LH and RH. NOTE: When separating the cylinder block, do not allow the connecting rod to fall or damage the cylinder block.

(5) (7) (1) (4)

(2) (4)

(6)

(3)

(1)

(5) ME-02890

(1) (2) (3)

Cylinder block Rear oil seal Crankshaft

(4) (5) (6)

Crankshaft bearing Piston Seal washer

33) Remove the rear oil seal. 34) Remove the crankshaft together with connecting rod. 35) Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: • Press the crankshaft bearing at the end opposite to locking lip to remove. • Be careful not to confuse the crankshaft bearing combination. 36) Remove each piston from the cylinder block using a wooden bar or hammer handle. NOTE: Be careful not to confuse the original combination of piston and cylinder.

ME(H4DOTC)-85

(7)

Washer

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Cylinder Block MECHANICAL

B: INSTALLATION (6)

(5)

(4)

(1)

(7)

(3)

(3)

(7) (6)

(2)

(7) (6)

ME-03186

(1) (2) (3)

Crankshaft bearing Crankshaft Cylinder block

(4) (5) (6)

Rear oil seal O-ring Seal washer

1) Remove oil on the mating surface of cylinder block before installation. Apply a coat of engine oil to the bearing and crankshaft journal. 2) Position the crankshaft and O-ring on cylinder block RH.

(7)

Washer

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

NOTE: Use new O-rings. 3) Apply liquid gasket to the mating surfaces of cylinder block RH, and position cylinder block LH. NOTE: • Install within 5 min. after applying liquid gasket. • Do not allow liquid gasket to jut into O-ring grooves, oil passages, bearing grooves, etc.

ME-00145

4) Apply a coat of engine oil to the washer and bolt thread. NOTE: Use a new seal washer. 5) Tighten the 10 mm cylinder block connecting bolts on the LH side (A — D) in alphabetical order.

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Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb)

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

(E)

(A)

(J)

(G)

(D)

(B) (C)

(I)

(H)

(F)

ME-00779

6) Tighten the 10 mm cylinder block connecting bolts on RH side (E — J) in alphabetical sequence.

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb)

(E)

ME-00780

9) Tighten the LH side cylinder block connecting bolts (A — D) further in alphabetical order. • (A), (C): Angle tightening

Tightening angle: 90° • (B), (D): Torque tightening Tightening torque: 40 N·m (4.1 kgf-m, 29.5 ft-lb)

(J)

(G)

(A) (I)

(H)

(F)

(D) ME-00780

7) Tighten the LH side cylinder block connecting bolts (A — D) further in alphabetical order.

(B) (C)

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

ME-00779

10) Tighten the RH side cylinder block connecting bolts (E — J) further in alphabetical order.

Tightening angle: 90°

(A) (D)

(B)

(E) (C)

(J)

(G) ME-00779

8) Tighten the RH side cylinder block connecting bolts (E — J) further in alphabetical order. (I)

(F)

(H) ME-00780

11) Tighten the 8 mm and 6 mm cylinder block connecting bolts on the LH side (A — H) in alphabetical order.

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Tightening torque: (A) — (G): 25 N·m (2.5 kgf-m, 18.4 ft-lb) (H): 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

15) Position the upper rail gap at (C) in the figure.

(G) (C)

(E)

(A)

(B)

25

(C) ME-03620 (D)

(F)

(H)

ME-00147

16) Align the upper rail spin stopper (E) to the side hole (D) on the piston.

12) Apply a coat of engine oil to the oil seal periphery and install the rear oil seal using ST1 and ST2.

(D)

(E)

NOTE: Use a new rear oil seal. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER (B)

(A)

ME-02471

17) Position the expander gap at (F) in the figure on the 180° opposite direction of (C).

ST2

(F)

ST1 ME-00148

(A) Rear oil seal (B) Flywheel attachment bolt

13) Position the top ring gap at (A) or (B) in the figure. 14) Position the second ring gap at 180° on the reverse side the top ring gap.

(A)

ME-03621

18) Set the lower rail gap at position (G), located 120° clockwise from (C).

(B)

(G)

(C)

120 ME-03619

ME-03622

NOTE: • Make sure ring gaps do not face the same direction. • Make sure ring gaps are not within the piston skirt area.

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Cylinder Block MECHANICAL

19) Install the snap ring. Before positioning the piston on the cylinder block, attach the snap ring in the service hole of the cylinder block and the piston hole on the opposite side. NOTE: Use new snap rings. #3

#1

#4

(A)

#2

ME-00306

(A) Front side (5)

T

(4) (1)

(5)

(3)

(4) (3)

(2)

(2)

(1)

ME-02442

(1) (2) (3)

Piston Piston pin Snap ring

(4) (5)

Gasket Service hole plug

ME(H4DOTC)-89

Tightening torque:N·m (kgf-m, ft-lb) T: 70 (7.1, 51.6)

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Cylinder Block MECHANICAL

20) Install the piston. (1) Set the parts so that the #1 and #2 cylinders are on the upper side. (2) Using the ST1, turn the crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET (3) Apply a coat of engine oil to the pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747300 PISTON GUIDE

(3) Apply a thin coat of engine oil to piston pin, and insert the piston pin into piston and connecting rod through service hole. (4) Install the snap ring. NOTE: Use new snap rings.

ST1

ME-00159

(5) Apply liquid gasket to the threaded portion of the service hole plug. ST2 ME-00157

NOTE: Face the piston front mark towards the front of the engine.

Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent

(A)

ME-00160

ME-00786

(A) Front mark

21) Install the piston pin. (1) Apply a thin coat of engine oil to ST3. (2) Insert ST3 into the service hole to align the piston pin hole and the connecting rod small end. ST3 499017100 PISTON PIN GUIDE ST1

ST3

ME-00158

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Cylinder Block MECHANICAL

(6) Install the service hole plug and gasket. NOTE: Use a new gasket.

Tightening torque: 70 N·m (7.1 kgf-m, 51.6 ft-lb)

ME-00140 (5)

T2

T1 (6)

(4)

(3)

(7)

(2) (1)

(3) (2)

(1) ME-02440

(1) (2) (3) (4)

Piston Piston pin Snap ring Gasket

(5) (6) (7)

Service hole plug Service hole cover O-ring

ME(H4DOTC)-91

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 70 (7.1, 51.6)

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Cylinder Block MECHANICAL

(7) Set the parts so that the #3 and #4 cylinders are on the upper side. Following the same procedures as used for #1 and #2 cylinders, install the pistons and piston pins. (8) Install the service hole cover.

Tightening torque: 6.5 N·m (0.7 kgf-m, 4.8 ft-lb) (A)

(C)

NOTE: Use new O-rings.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 22) Install the water by-pass pipe. (B)

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

(D)

T2

T1 T1

ME-04394

24) Install the baffle plate. NOTE: • Use a new seal. • Make sure that the seals (A) are installed securely on the baffle plate in a direction as shown in the figure below. (A)

ME-04326

23) Install blow-by pipe assembly (A), blow-by pipe (B), PCV hose assembly (C) and water pipe assembly (D). NOTE: For the blow-by pipe assembly (A), blow-by pipe (B) and PCV hose assembly (C), use a new clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp. ST 18353AA000 CLAMP PLIERS

LU-00052

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 25) Apply liquid gasket to the mating surfaces of cylinder block lower, and install the cylinder block lower. CAUTION: Be careful not to apply any liquid gasket to the O-ring attachment section.

ST

ME-04374

NOTE: • Use new O-rings. • Before installing the cylinder block lower, clean the mating surface of cylinder block lower and cylinder block. • Install within 5 min. after applying liquid gasket.

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Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

(A)

LU-02583 LU-02581

(A) O-ring

27) Secure the oil level switch harness to the cylinder block with clip.

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

ME-04392

T2

T1 ME-04327

26) Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan. NOTE: • Before installing the oil pan, clean the mating surface of oil pan and cylinder block. • Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

28) Apply liquid gasket to the mating surface of oil separator cover and the threaded portion of bolt (A) shown in the figure (when reusing the bolt), and then install the oil separator cover. NOTE: • Install within 5 min. after applying liquid gasket. • Use new oil separator cover.

Liquid gasket: Mating surface THREE BOND 1217G (Part No. K0877Y0100) or equivalent Bolt thread (A) (when reusing the bolt) THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) (A)

LU-02580

ME-03333

29) Install the flywheel.

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30) Install the clutch disc and cover. 31) Install the oil pump. (1) Using the ST, install the front oil seal. ST 499587100 OIL SEAL INSTALLER NOTE: Use a new front oil seal.

• Make sure the front oil seal lip is not folded. NOTE: • Align the flat surface of oil pump’s inner rotor with flat surface of crankshaft before installation. • Use new O-rings. • Do not forget to assemble O-rings. (5) Apply liquid gasket to the three bolts thread shown in figure. (when reusing bolts)

Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

ST

LU-00021

(2) Apply liquid gasket to the mating surfaces of oil pump. NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

T

ME-04112

32) Install the water pump and gasket. NOTE: • When installing the water pump, tighten bolts in two stages in alphabetical order as shown in the figure. • Use a new gasket. • Use new water pump sealing.

(A)

ME-00165

(A) O-ring

(3) Apply a thin coat of engine oil to the inside of front oil seal.

ME-00312

(4) Install the oil pump to cylinder block. CAUTION: • Be careful not to damage the front oil seal during installation.

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Tightening torque: First: 12 N·m (1.2 kgf-m, 8.9 ft-lb) Second: 12 N·m (1.2 kgf-m, 8.9 ft-lb)

(1) Install the rocker cover gasket to the rocker cover. (Outer periphery and ignition coil section) NOTE: Use a new rocker cover gasket. (2) Apply liquid gasket to the specified point of the cylinder head.

(B)

NOTE: Install within 5 min. after applying liquid gasket.

(C) (A)

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

(D)

(E)

(F)

CO-02578

33) Install the hose to water pump. 34) Install the oil cooler. (MT model) 35) Install the oil filter. 36) Install the cylinder head. 37) Install the camshaft. 38) Install the A/C compressor together with the bracket.

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb) 39) Install the crank sprocket. 40) Install the cam sprocket. 41) Install the timing belt. 42) Adjust the valve clearance. 43) Install the rocker cover.

ME-04321

(3) Install the rocker cover to cylinder head. Ensure the gasket is properly positioned during installation. (4) Temporarily tighten the rocker cover bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order.

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Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) (C),(K)

(E)

(H)

(B),(J)

(A),(I)

(F)

(G)

(D),(L) (C),(K)

(H)

(E)

(B),(J) (A),(I)

(G)

(D),(L)

(F)

ME-04351

44) Connect the PCV hose to the rocker cover. 45) Install the timing belt cover. 46) Install the crank pulley. 47) Install the intake manifold.

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C: DISASSEMBLY (1) (2)

(2)

(7)

(5) (4) (3) (6)

ME-03556

(1) (2) (3)

Connecting rod cap Connecting rod bearing Top ring

(4) (5)

Second ring Oil ring

1) Remove the connecting rod cap. 2) Remove the connecting rod bearing. NOTE: Keep the removed connecting rods, connecting rod caps and bearings in order so that they are kept in their original combinations/groups, and not mixed together. 3) Remove the piston rings using piston ring expander. 4) Remove the oil ring by hand. NOTE: Arrange the removed piston rings in proper order, to prevent confusion. 5) Remove the snap ring.

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(6) (7)

Snap ring Connecting rod

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D: ASSEMBLY T

(3) (1)

(1) (2)

(4) (5)

(8)

(6)

(7)

ME-02985

(1) (2) (3) (4)

Connecting rod bearing Connecting rod Connecting rod cap Oil ring

(5) (6) (7) (8)

Second ring Top ring Snap ring Side mark

1) Apply engine oil to the surface of the connecting rod bearings, and install the connecting rod bearings onto connecting rods and connecting rod caps. 2) Position each connecting rod with the side with a side mark facing forward, and install it. 3) Attach the connecting rod cap, and tighten with the connecting rod bolt. Make sure the arrow on connecting rod cap faces the front during installation. NOTE: • Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. • When tightening the connecting rod bolts, apply oil on the threads.

Tightening torque: 52 N·m (5.3 kgf-m, 38.4 ft-lb) 4) Install the oil ring upper rail, expander and lower rail by hand. 5) Install the second ring and top ring using piston ring expander.

Tightening torque:N·m (kgf-m, ft-lb) T: 52 (5.3, 38.4)

E: INSPECTION 1. CYLINDER BLOCK 1) Check for cracks or damage. Use liquid penetrant tester on the important sections to check for fissures. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Check the oil passages for clogging. 3) Inspect the cylinder block surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary.

Warping limit: 0.025 mm (0.00098 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)

NOTE: Assemble so that the piston ring mark “R” faces the top side of the piston.

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2. CYLINDER AND PISTON 1) The cylinder bore size is stamped on the front upper face of the cylinder block.

Out-of-roundness: Standard 0.010 mm (0.0004 in)

NOTE: • Measurement should be performed at a temperature of 20°C (68°F). • Standard sized pistons are classified into two grades, “A” and “B”. These grades should be used as guide lines in selecting a standard piston.

(A)

(B)

Standard diameter: A: 99.505 — 99.515 mm (3.9175 — 3.9179 in) B: 99.495 — 99.505 mm (3.9171 — 3.9175 in)

H1 H2 H3 H4

(B)

#5

4

5

ME-00171

#4

5

4

(A)

(A) (B) H1: H2: H3: H4:

A

A

#1

B

#2

(F)

B

#3 (D)

(E) (C) ME-00170

(A) (B) (C) (D) (E) (F)

Main journal size mark Cylinder block (RH) – (LH) combination mark #1 cylinder bore size mark #2 cylinder bore size mark #3 cylinder bore size mark #4 cylinder bore size mark

2) Measure inner diameter of each cylinder. Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge.

Piston pin direction Thrust direction 10 mm (0.39 in) 45 mm (1.77 in) 80 mm (3.15 in) 115 mm (4.53 in)

3) When the piston is to be replaced due to general or cylinder wear, select a suitable sized piston by measuring the piston clearance. 4) Measure outer diameter of each piston. Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction) NOTE: Measurement should be performed at a temperature of 20°C (68°F).

Piston grade point H: 38.2 mm (1.50 in) Piston outer diameter:

NOTE: Measurement should be performed at a temperature of 20°C (68°F).

Taper: Standard 0.015 mm (0.0006 in)

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Standard A: 99.505 — 99.515 mm (3.9175 — 3.9179 in) B: 99.495 — 99.505 mm (3.9171 — 3.9175 in) 0.25 mm (0.0098 in) oversize 99.745 — 99.765 mm (3.9270 — 3.9278 in) 0.50 mm (0.0197 in) oversize 99.995 — 100.015 mm (3.9368 — 3.9376 in)

3) Make sure the piston pin can be inserted into the piston pin hole by a thumb at 20°C (68°F). Replace if faulty.

Clearance between piston pin hole and piston pin: Standard 0.004 — 0.008 mm (0.0002 — 0.0003 in)

H ME-00172

ME-00173

5) Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20°C (68°F).

Cylinder to piston clearance at 20°C (68°F): Standard –0.010 — 0.010 mm (–0.00039 — 0.00039 in) 6) Boring and honing (1) If any of the measured value of taper, out-ofroundness or cylinder-to-piston clearance is out of standard or if there is any damage on the cylinder wall, rebore it to replace with an oversize piston.

ME-00174

4) Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.

CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and replaced with oversize pistons. (2) If the cylinder inner diameter exceeds the limit after boring and honing, replace the cylinder block. NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, when measuring the cylinder diameter, wait until it has cooled to room temperature.

(A)

ME-00175

5) Check the piston pin snap ring for distortion, cracks and wear.

Cylinder inner diameter boring limit (diameter): To 100.005 mm (3.9372 in)

3. PISTON AND PISTON PIN 1) Check the piston and piston pin for damage, cracks or wear. Replace if faulty. 2) Check the piston ring groove for wear or damage. Replace if faulty.

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4. PISTON RING 1) If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of the same size as piston. NOTE: • The top ring and second ring have the mark to determine the direction for installing. When attaching the ring to the piston, face these marks towards the top side. • Oil ring consists of the upper rail, expander and lower rail. When attaching the oil ring to the piston, pay attention to the direction of each rail.

2) Using the piston, insert the piston ring and oil ring into the cylinder so that they are perpendicular to the cylinder wall, and measure the piston ring gap with a thickness gauge.

Top ring Piston ring gap

Standard mm (in) 0.20 — 0.25 (0.0079 — 0.0098)

Second ring

0.37 — 0.52 (0.015 — 0.020)

Oil ring rail

0.20 — 0.50 (0.0079 — 0.0197)

(A) (B) (C)

ME-00177

3) Fit the piston ring straight into the piston ring groove, then measure the clearance between piston ring and piston ring groove with a thickness gauge.

(A)

(B)

NOTE: Before measuring the clearance, clean the piston ring groove and piston ring.

(C)

Standard mm (in) ME-02480

(A) Upper rail (B) Expander (C) Lower rail

Clearance between Top ring piston ring and piston ring groove Second ring

0.040 — 0.080 (0.0016 — 0.0031) 0.030 — 0.070 (0.0012 — 0.0028)

ME-00178

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5. CONNECTING ROD 1) Replace the connecting rod, if the large or small end thrust surface is damaged. 2) Check for bend or twist using a connecting rod aligner. Replace the connecting rod if the bend or twist exceeds the limit.

Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in)

5) Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary.

Connecting rod oil clearance: Standard 0.017 — 0.045 mm (0.0007 — 0.0018 in) Unit: mm (in) Bearing

(A)

Standard (B)

0.03 (0.0012) Undersize 0.05 (0.0020) Undersize 0.25 (0.0098) Undersize

Bearing size (Thickness at center)

Outer diameter of crank pin

1.490 — 1.506 (0.0587 — 0.0593) 1.504 — 1.512 (0.0592 — 0.0595) 1.514 — 1.522 (0.0596 — 0.0599) 1.614 — 1.622 (0.0635 — 0.0639)

51.976 — 52.000 (2.0463 — 2.0472) 51.954 — 51.970 (2.0454 — 2.0461) 51.934 — 51.950 (2.0447 — 2.0453) 51.734 — 51.750 (2.0368 — 2.0374)

6) Inspect the bushing at connecting rod small end, and replace with a new part if worn or damaged. 7) Measure the piston pin clearance at connecting rod small end. Replace it with a new part if the value is not within the standard,

(A)

Clearance between piston pin and bushing: Standard 0 — 0.022 mm (0 — 0.0009 in)

(B)

ME-00179

(A) Thickness gauge (B) Connecting rod

3) Install the connecting rod with bearings attached to the crankshaft, and using a thickness gauge, measure the thrust clearance. If the thrust clearance exceeds the standard or uneven wear is found, replace the connecting rod.

ME-00181

Connecting rod thrust clearance: Standard 0.070 — 0.330 mm (0.0028 — 0.0130 in)

ME-00174

ME-00180

4) Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.

8) The replacement procedure for the connecting rod small end bushing is as follows. (1) Remove the bushing from connecting rod with ST and press.

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(2) Apply oil on the periphery of the new bushing, and press the bushing in with the ST. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER

Crank pin: Out-of-roundness 0.003 mm (0.0001 in) Cylindricality 0.004 mm (0.0002 in) Grinding limit (dia.) To 51.750 mm (2.0374 in) Crank journal: Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit (dia.) To 59.758 mm (2.3527 in)

ST

ME-00182

(3) Make two 3 mm (0.12 in) holes in the pressed bushing to match the pre-manufactured holes on the connecting rod, then ream the inside of the bushing. (4) After completion of reaming, clean the bushing to remove chips.

6. CRANKSHAFT AND CRANKSHAFT BEARING 1) Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. If defective, replace the crankshaft. 2) Measure warping of the crankshaft. If it exceeds the limit, correct or replace it. NOTE: If a suitable V-block is not available, using just the #1 and #5 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge.

Crankshaft bend limit: 0.035 mm (0.0014 in)

ME-00183

3) Inspect the crank journal and crank pin for wear. If they are not within the standard, replace the bearing with a suitable (undersize) one, and replace or grind to correct the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used.

ME(H4DOTC)-103

ME-00184

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Cylinder Block MECHANICAL Unit: mm (in) Crank journal diameter #2, #4, #5 59.984 — 60.008 (2.3616 — 2.3625) 2.000 — 2.017 (0.0787 — 0.0794)

59.962 — 59.978 (2.3607 — 2.3613) 2.017 — 2.020 (0.0794 — 0.0795)

59.962 — 59.978 (2.3607 — 2.3613) 2.019 — 2.022 (0.0795 — 0.0796)

51.954 — 51.970 (2.0454 — 2.0461) 1.504 — 1.512 (0.0592 — 0.0595)

Journal O.D.

59.942 — 59.958 (2.3599 — 2.3605)

59.942 — 59.958 (2.3599 — 2.3605)

51.934 — 51.950 (2.0447 — 2.0453)

Bearing size (Thickness at center)

2.027 — 2.030 (0.0798 — 0.0799)

2.029 — 2.032 (0.0799 — 0.0800)

1.514 — 1.522 (0.0596 — 0.0599)

59.742 — 59.758 (2.3520 — 2.3527) 2.127 — 2.130 (0.0837 — 0.0839)

59.742 — 59.758 (2.3520 — 2.3527) 2.129 — 2.132 (0.0838 — 0.0839)

51.734 — 51.750 (2.0368 — 2.0374) 1.614 — 1.622 (0.0635 — 0.0639)

Journal O.D. Standard

0.03 (0.0012) Undersize

0.05 (0.0020) Undersize

0.25 (0.0098) Undersize

Crank pin outer diameter

#1, #3 59.984 — 60.008 (2.3616 — 2.3625) 1.998 — 2.015 (0.0787 — 0.0793)

Bearing size (Thickness at center) Journal O.D. Bearing size (Thickness at center)

Journal O.D. Bearing size (Thickness at center)

4) Use a thickness gauge to measure the thrust clearance of crankshaft at #5 crank journal bearing. If clearance exceeds the standard, replace the bearing.

Crankshaft thrust clearance: Standard 0.030 — 0.115 mm (0.0012 — 0.0045 in)

ME-00322

5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear. 6) Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or grind to correct the crankshaft as necessary.

Crankshaft oil clearance: Standard 0.010 — 0.030 mm (0.00039 — 0.0012 in)

ME(H4DOTC)-104

51.976 — 52.000 (2.0463 — 2.0472) 1.490 — 1.506 (0.0587 — 0.0593)

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Intake and Exhaust Valve MECHANICAL

21.Intake and Exhaust Valve A: SPECIFICATION Refer to “Cylinder Head” for removal and installation procedures of the intake and exhaust valves.

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Piston MECHANICAL

22.Piston A: SPECIFICATION Refer to “Cylinder Block” for removal and installation procedures of pistons.

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Connecting Rod MECHANICAL

23.Connecting Rod A: SPECIFICATION Refer to “Cylinder Block” for removal and installation procedures of connecting rod.

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Crankshaft MECHANICAL

24.Crankshaft A: SPECIFICATION Refer to “Cylinder Block” for removal and installation procedures of the crankshaft.

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Engine Trouble in General MECHANICAL

25.Engine Trouble in General A: INSPECTION NOTE: The “RANK” shown in the chart shows the possibilities of the cause of trouble in order from “Very often” to “Rarely”. A — Very often B — Sometimes C — Rarely Symptoms 1. Engine does not start. 1) Starter does not turn.

2) Initial combustion does not occur.

Problem parts etc. Starter

Possible cause

Defective battery-to-starter harness Defective starter switch Defective starter Battery Improper connection of terminal Run-down battery Defective charging system Friction Seizure of crankshaft and connecting rod bearing Seized camshaft Seized or stuck piston and cylinder Immobilizer system Starter Defective starter Engine control system Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity)

ME(H4DOTC)-109

RANK B C B A A B C C C A C A A C B B B C C C C C B C B B

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Engine Trouble in General MECHANICAL Symptoms 3) Initial combustion occurs.

4) Engine stalls after initial combustion.

Problem parts etc. Possible cause Engine control system Intake system Defective intake manifold gasket Defective throttle body gasket Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element Fuel line Clogged fuel line Lack of fuel or insufficient fuel Timing belt Degradation, etc. Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity)

ME(H4DOTC)-110

RANK A B B C C B B B C C C C C B C B B A B C C B B C C B B B C C C C C B C B B

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Engine Trouble in General MECHANICAL Symptoms 2. Rough idle and engine stall

Problem parts etc. Possible cause Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Defective rocker cover gasket Cooling system Over-heating Others Evaporative emission control system malfunction Stuck or damaged throttle valve

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RANK A A A A B B C B C C C B C B B B B C B B A B B C C A B

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Engine Trouble in General MECHANICAL Symptoms 3. Low output, hesitation and poor acceleration

Problem parts etc. Possible cause Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Cooling system Over-heating Over-cooling Others Evaporative emission control system malfunction

ME(H4DOTC)-112

RANK A A A B B B B B A B B C B B B B B C B C A B B C C A

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Engine Trouble in General MECHANICAL Symptoms 4. Surging

5. Engine does not return to idle. 6. Dieseling (Run-on)

7. After burning in exhaust system

Problem parts etc. Possible cause Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Cooling system Over-heating Others Evaporative emission control system malfunction Engine control system Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve Engine control system Cooling system Over-heating Others Evaporative emission control system malfunction Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective PCV valve Loosened oil filler cap Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over-cooling Others Evaporative emission control system malfunction

ME(H4DOTC)-113

RANK A A A A B B B B B B B C B B C C C C C C A B B C A A A A B B A C C B B C B B C C B C C C A C C C

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Engine Trouble in General MECHANICAL Symptoms 8. Knocking

Problem parts etc. Possible cause Engine control system Intake system Loosened oil filler cap Timing belt Defective timing Compression Incorrect valve clearance Incorrect valve timing Cooling system Over-heating 9. Excessive engine oil con- Intake system Loosened or cracked PCV hose sumption Defective PCV valve Loosened oil filler cap Compression Defective valve stem Worn or stuck piston rings, cylinder and piston Lubrication system Loosened oil pump attaching bolts and defective gasket Defective oil filter gasket Defective crankshaft oil seal Defective rocker cover gasket Loosened oil drain plug or defective gasket Loosened oil pan fitting bolts or defective oil pan 10. Excessive fuel consump- Engine control system tion Intake system Dirty air cleaner element Timing belt Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective cylinder head gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Lubrication system Cooling system

Incorrect valve timing Incorrect oil pressure Over-cooling

ME(H4DOTC)-114

RANK A B B C B A A B C A A B B B B B B A A B B C C B C C B B C C

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Engine Noise MECHANICAL

26.Engine Noise A: INSPECTION Type of sound

Condition

Possible cause

• • Regular clicking sound • • • Oil pressure is low. • Heavy and dull clank Oil pressure is normal. • • Sound is noticeable when • accelerating with an overload High-pitched clank • condition. • • Noise is reduced when fuel Clank when engine speed is injector connector of noisy cyl- • between 1,000 and 2,000 rpm. inder is disconnected. * • Noise is reduced when fuel injector connector of noisy cyl- • Knocking sound when engine inder is disconnected. * • is operating under idling speed Sound is not reduced if each • and engine is warm fuel injector connector is dis• connected in turn. * • Squeaky sound — • Rubbing sound — • Gear scream when starting • — engine • Sound like polishing glass with • — a dry cloth • Sound increases as engine speed increases.

Hissing sound



Timing belt noise



Valve noise



Valve mechanism is defective. Incorrect valve clearance Worn camshaft Broken valve spring Worn crankshaft main bearing Worn connecting rod bearing (large end) Damaged engine mounting Ignition timing advanced Accumulation of carbon inside combustion chamber Wrong heat range of spark plug Improper octane value gasoline Worn crankshaft main bearing Worn connecting rod bearing (large end) Worn cylinder liner and piston ring Broken or stuck piston ring Worn piston pin and hole at piston end of connecting rod Unusually worn valve lifter Worn cam sprocket Worn camshaft journal bore in cylinder head Insufficient generator lubrication Poor contact of generator brush and rotor Defective ignition starter switch Worn gear and starter pinion Loose V-belt Defective water pump shaft

• Insufficient compression • Air leakage in air intake system, hose, connection or manifold • Loose timing belt • Timing belt contacting with adjacent part • Incorrect valve clearance

*

When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory. Therefore, perform the Clear Memory Mode and Inspection Mode after connecting the fuel injector connector.

ME(H4DOTC)-115

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Engine Noise MECHANICAL

ME(H4DOTC)-116

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EXHAUST

EX(H4DOTC) 1. 2. 3. 4. 5.

Page General Description ...................................................................................2 Front Exhaust Pipe .....................................................................................5 Center Exhaust Pipe ................................................................................12 Rear Exhaust Pipe ...................................................................................15 Muffler ......................................................................................................16

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General Description EXHAUST

1. General Description A: COMPONENT 1. FRONT EXHAUST PIPE T1

(1)

T1 E A C

B

D

(2) T1

T3

(3) T3

(6)

(2)

(14) (7)

(8) (4)

T2 C

(9)

T3

D

E

(10)

(5) F G

(11) T3 A

(14)

H

(13) B

F

T1

(12)

G H

T2

T1 T1 EX-02543

(1) (2) (3) (4) (5) (6) (7)

Exhaust pipe cover Gasket Front exhaust pipe Gasket Exhaust pipe stay Intake duct O-ring

(8) (9) (10) (11) (12) (13) (14)

Turbocharger Gasket Center exhaust pipe (Front) Turbocharger upper stay Turbocharger lower stay Engine cover Self-locking nut

EX(H4DOTC)-2

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 33 (3.4, 24.3) T3: 42.5 (4.3, 31.3)

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General Description EXHAUST

2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER (25)

(20)

(20)

T1

(20)

(23)

(25)

(22) (24)

(21)

T7

T7

(24)

(20) T1

(21) (17)

(18)

(20)

(16)

(21) T7 T7

(21)

(15)

T4

(19)

(26)

T1

B (6)

T5 T1 T8

T1

T3 B

(12)

(4) (8)

A

T6

(1)

T3 (11)

T9

(9) (2)

(10) (3) (14)

(5)

(13)

A (7)

T2

T2

EX-02574

EX(H4DOTC)-3

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General Description EXHAUST (1)

Center exhaust pipe (Front)

(14)

Center exhaust pipe band

(2) (3) (4)

Front catalytic converter Rear catalytic converter Center exhaust pipe inner cover (Front)

(15) (16) (17)

Gasket Rear exhaust pipe Spring

(5)

(18)

BOLT

T4: 23 (2.3, 17.0)

(19)

Chamber

T5: 35 (3.6, 25.8)

(20)

Cushion rubber

T6: 42.5 (4.3, 31.3)

(8) (9)

Center exhaust pipe outer cover (Front) Center exhaust pipe upper cover (Front) Center exhaust pipe lower cover (Front) Front oxygen (A/F) sensor Rear oxygen sensor

(21) (22)

Self-locking nut Muffler RH

(10)

Gasket

(23)

Muffler LH

T7: 48 (4.9, 35.4) T8: T9:

(11) (12)

Center exhaust pipe (Rear) Center exhaust pipe upper cover (Rear) Center exhaust pipe lower cover (Rear)

(24) (25)

Gasket Muffler cutter

(26)

Hanger bracket

(6) (7)

(13)

Tightening torque:N·m (kgf-m, ft-lb) T1: 7.5 (0.8, 5.5) T2: 13 (1.3, 9.6) T3: 18 (1.8, 13.3)

B: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. • If any fat adheres to the exhaust pipe, wipe it off. Otherwise a fire may happen.

C: PREPARATION TOOL 1. GENERAL TOOL TORX

®

TOOL NAME socket E10

REMARKS Used for removing and installing center exhaust pipe (front).

EX(H4DOTC)-4

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Front Exhaust Pipe EXHAUST

2. Front Exhaust Pipe

9) Disconnect the engine coolant hose from the water tank pipe and water pump.

A: REMOVAL CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Remove the collector cover. 2) Disconnect the ground cable from battery.

IG-02107

3) Remove the air intake duct. 4) Lift up the vehicle. 5) Remove the under cover. 6) Drain engine coolant. 7) Lower the vehicle. 8) Disconnect connectors from the front oxygen (A/ F) sensor and rear oxygen sensor, and remove the clip (A) fastening the front oxygen (A/F) sensor harness and rear oxygen sensor harness.

EX-02576

10) Remove the radiator sub fan motor assembly.

11) Remove the engine coolant hose from clip (A), and remove the bolts which secure the intake duct to the turbocharger. (A)

EX-02567

(A)

EX-02575

12) Lift up the vehicle. 13) Remove oil inlet pipe B (B) from oil inlet pipe A (A), and remove the bolt which holds oil inlet pipe C (C) and oil inlet pipe A (A).

EX(H4DOTC)-5

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Front Exhaust Pipe EXHAUST

CAUTION: In order to prevent damaging the oil inlet pipe, fix the section (a) shown in the figure when loosing the oil inlet pipe flare nut, and avoid the part from rotating together while loosening the nut.

16) Remove the rear exhaust pipe from the center exhaust pipe (rear).

EX-02561 (a)

EX-02549

17) Remove the bolt which holds center exhaust pipe (rear) to the hanger bracket, and remove the center exhaust pipe (rear).

(C)

(B)

(A) EX-02562 EX-02550

18) Remove the engine cover.

14) Disconnect the air control hose (A), and loosen the bolts which secure the intake duct to the turbocharger.

(A) EX-02589

IN-02735

15) Remove the center exhaust pipe (rear) from the center exhaust pipe (front).

19) Remove bolts and nuts which secure the oil catch tank to the turbocharger and oil catch tank stay, and remove the oil catch tank from the turbocharger.

EX-02590 EX-02552

EX(H4DOTC)-6

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Front Exhaust Pipe EXHAUST

20) Remove the bolts which secure the turbocharger stay.

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

EX-02591

21) While holding the front exhaust pipe with transmission jack, remove the nuts which hold the front exhaust pipe to the cylinder head exhaust port, and remove the front exhaust pipe.

EX-02591

3) Set the oil catch tank to the turbocharger, and attach the bolt and nut which secure the oil catch tank to the turbocharger and oil catch tank stay. NOTE: • Use a new gasket. • When installing the oil catch tank, tighten to the specified torque in the alphabetical order shown in the figure.

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 10.5 N·m (1.1 kgf-m, 7.7 ft-lb) EX-02592

B: INSTALLATION 1) While holding the front exhaust pipe with transmission jack, set the front exhaust pipe, and install the nuts which hold the front exhaust pipe to the cylinder head exhaust port.

T1 (a) (b)

T2

(c)

NOTE: Use a new gasket.

EX-02593

4) Install the engine cover.

Tightening torque: 42.5 N·m (4.3 kgf-m, 31.3 ft-lb)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

EX-02592

2) Attach the bolt which holds the turbocharger stay.

EX(H4DOTC)-7

EX-02589

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Front Exhaust Pipe EXHAUST

5) Install the center exhaust pipe (rear) and temporarily tighten the bolt which holds center exhaust pipe (rear) to the hanger bracket.

Tightening torque: 35 N·m (3.6 kgf-m, 25.8 ft-lb)

EX-02562 EX-02562

6) Install the rear exhaust pipe to the center exhaust pipe (rear). NOTE: Use a new gasket.

9) Install the bolts which secure the intake duct to the turbocharger, and connect the air control hose (A). NOTE: • Use new O-rings. • Be careful not to pinch the O-ring.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(A)

EX-02561

7) Assemble the center exhaust pipe (rear) to the center exhaust pipe (front). NOTE: Use a new gasket.

IN-02735

10) Install the bolt which holds oil inlet pipe C (C) and oil inlet pipe A (A), and install oil inlet pipe B (B) to oil inlet pipe A (A). CAUTION: In order to prevent damaging the oil inlet pipe, fix the section (a) shown in the figure when tightening the oil inlet pipe flare nut, and avoid the part from rotating together while tightening the nut.

Tightening torque: 42.5 N·m (4.3 kgf-m, 31.3 ft-lb)

EX-02552

8) Tighten the bolts which hold center exhaust pipe (rear) to the hanger bracket.

(a)

EX-02549

EX(H4DOTC)-8

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Front Exhaust Pipe EXHAUST

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 20 N·m (2.0 kgf-m, 14.8 ft-lb)

(C)

(B)

T2

15) Connect the engine coolant hoses to the water tank pipe and water pump.

T1

(A)

EX-02555

11) Install the under cover. 12) Lower the vehicle. 13) Install the engine coolant hose to the clip (A), and install the bolts which secure the intake duct to the turbocharger.

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb) (A)

EX-02576

16) Connect connectors to the front oxygen (A/F) sensor and rear oxygen sensor, and secure the front oxygen (A/F) sensor harness and rear oxygen sensor harness with the clip (A).

EX-02567

14) Install the radiator sub fan motor assembly.

(A)

EX-02575

17) Install the air intake duct. 18) Connect the ground cable to battery.

IG-02107

EX(H4DOTC)-9

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Front Exhaust Pipe EXHAUST

19) Fill engine coolant. 20) Install the collector cover.

4) Remove the exhaust pipe stay from the front exhaust pipe.

C: DISASSEMBLY 1) Remove the exhaust pipe cover.

EX-02560

D: ASSEMBLY 1) Install the exhaust pipe stay to the front exhaust pipe. EX-02594

2) Remove nuts which secure the center exhaust pipe (front) to the turbocharger, and remove the center exhaust pipe (front) together with turbocharger upper stay (A) and turbocharger lower stay (B).

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

(A)

EX-02560

2) Install the turbocharger to the front exhaust pipe.

(B) EX-02595

3) Remove the turbocharger from the front exhaust pipe.

NOTE: Use a new gasket and self-locking nut.

Tightening torque: 42.5 N·m (4.3 kgf-m, 31.3 ft-lb)

EX-02596

EX-02596

3) Install the center exhaust pipe (front) to the turbocharger together with turbocharger upper stay (A) and turbocharger lower stay (B). NOTE: Use a new gasket and self-locking nut.

EX(H4DOTC)-10

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Front Exhaust Pipe EXHAUST

Tightening torque: 42.5 N·m (4.3 kgf-m, 31.3 ft-lb) (A)

(B) EX-02595

4) Install the exhaust pipe cover.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

EX-02594

E: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting.

EX(H4DOTC)-11

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Center Exhaust Pipe EXHAUST

3. Center Exhaust Pipe

7) Remove the rear exhaust pipe from the center exhaust pipe (rear).

A: REMOVAL 1) Remove the collector cover. 2) Disconnect the ground cable from battery.

EX-02561

IG-02107

8) Remove the bolt which holds center exhaust pipe (rear) to the hanger bracket, and remove the center exhaust pipe (rear).

3) Disconnect connectors from the front oxygen (A/ F) sensor and rear oxygen sensor, and remove the clip (A) fastening the front oxygen (A/F) sensor harness and rear oxygen sensor harness.

EX-02562

9) Remove the bolts which secure the turbocharger stay.

(A)

EX-02575

4) Lift up the vehicle. 5) Remove the under cover. 6) Remove the center exhaust pipe (front) from the center exhaust pipe (rear).

EX-02570

10) Remove the bolts which hold the oil catch tank stay and engine cover to the turbocharger lower stay.

EX-02552

EX-02556

EX(H4DOTC)-12

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Center Exhaust Pipe EXHAUST

11) Remove nuts which hold center exhaust pipe (front) to the turbocharger, and remove the turbocharger lower stay (A).

Tightening torque: 42.5 N·m (4.3 kgf-m, 31.3 ft-lb)

(A)

(B)

(A)

EX-02571 EX-02568

12) Using the TORX® socket E10, remove bolts from the turbocharger, and remove the center exhaust pipe (front) together with turbocharger upper stay (A).

3) Install bolts which hold the oil catch tank stay and engine cover to the turbocharger lower stay.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(A)

EX-02556

EX-02569

4) Attach the bolt which holds the turbocharger stay.

B: INSTALLATION 1) Set the center exhaust pipe (front) together with turbocharger upper stay (A), and install stud bolts to the turbocharger by using the TORX® socket E10.

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

NOTE: Use a new gasket.

Tightening torque: 14.7 N·m (1.5 kgf-m, 10.8 ft-lb)

EX-02570

(A)

EX-02569

2) Install the center exhaust pipe (front) to the turbocharger together with turbocharger upper stay (A) and turbocharger lower stay (B). NOTE: Use a new self-locking nut.

EX(H4DOTC)-13

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Center Exhaust Pipe EXHAUST

5) Install the center exhaust pipe (rear) and temporarily tighten the bolt which holds center exhaust pipe (rear) to the hanger bracket.

Tightening torque: 35 N·m (3.6 kgf-m, 25.8 ft-lb)

EX-02562 EX-02562

6) Install the rear exhaust pipe to the center exhaust pipe (rear). NOTE: Use a new gasket.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

9) Install the under cover. 10) Lower the vehicle. 11) Connect connectors to the front oxygen (A/F) sensor and rear oxygen sensor, and secure the front oxygen (A/F) sensor harness and rear oxygen sensor harness with the clip (A).

(A)

EX-02575 EX-02561

7) Install the center exhaust pipe (front) to the center exhaust pipe (rear).

12) Connect the ground cable to battery.

NOTE: Use a new gasket.

Tightening torque: 42.5 N·m (4.3 kgf-m, 31.3 ft-lb)

IG-02107

13) Install the collector cover.

C: INSPECTION

EX-02552

1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting.

8) Tighten the bolts which hold center exhaust pipe (rear) to the hanger bracket.

EX(H4DOTC)-14

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Rear Exhaust Pipe EXHAUST

4. Rear Exhaust Pipe A: REMOVAL CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Lift up the vehicle. 2) Remove the center exhaust pipe (rear) from the rear exhaust pipe.

NOTE: After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.

EX-02578

3) Install the muffler to the rear exhaust pipe. NOTE: Use a new gasket and self-locking nut. EX-02561

Tightening torque: 48 N·m (4.9 kgf-m, 35.4 ft-lb)

3) Remove the muffler from rear exhaust pipe. CAUTION: Be careful not to drop the rear exhaust pipe.

EX-02564

4) Install the center exhaust pipe (rear) to the rear exhaust pipe. EX-02564

4) Apply a coat of spray type lubricant to the mating area of cushion rubber. 5) Remove the rear exhaust pipe from the cushion rubber.

NOTE: Use a new gasket.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

EX-02561 EX-02578

5) Lower the vehicle.

B: INSTALLATION

C: INSPECTION

1) Apply a coat of spray type lubricant to the mating area of cushion rubber. 2) Install the rear exhaust pipe to the cushion rubber.

1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting. 3) Check the cushion rubber for wear or crack.

EX(H4DOTC)-15

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Muffler EXHAUST

5. Muffler

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Lift up the vehicle. 2) Remove the rear exhaust pipe from the muffler.

NOTE: • Use a new gasket and self-locking nut. • After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.

Tightening torque: 48 N·m (4.9 kgf-m, 35.4 ft-lb)

EX-02564

3) Apply a coat of spray type lubricant to the mating area of cushion rubber. 4) Remove the muffler from the cushion rubber. CAUTION: Be careful not to drop the muffler during removal.

EX-02564

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting. 3) Check the cushion rubber for wear or crack.

EX-02566

EX(H4DOTC)-16

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COOLING

CO(H4DOTC) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Page General Description ...................................................................................2 Radiator Fan System .................................................................................7 Engine Coolant .........................................................................................14 Water Pump .............................................................................................16 Thermostat ...............................................................................................19 Radiator ....................................................................................................21 Radiator Cap ............................................................................................24 Radiator Main Fan and Fan Motor ...........................................................25 Radiator Sub Fan and Fan Motor .............................................................27 Reservoir Tank .........................................................................................29 Engine Cooling System Trouble in General .............................................30

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General Description COOLING

1. General Description A: SPECIFICATION Electric fan + Forced engine coolant circulation system 2 (US qt, Imp qt) Approx. 6.6 (7.0, 5.8) Centrifugal impeller type

Cooling system Total engine coolant capacity Type

Discharge rate 2 (US gal, Imp gal) /min. Pump speed — Discharge pressure Engine coolant temperature Impeller diameter mm (in) Number of impeller vanes Pump pulley diameter mm (in) Clearance between impeller and mm (in) Standard pump case

200 (52.8, 44.0) 6,000 rpm — 225.4 kPa (23.0 mAq) 80°C (176°F) 76 (2.99) 8 60 (2.36)

Discharge performance Water pump

Thermostat

Radiator fan

Radiator

Type Starting temperature to open Fully opens Valve lift Valve bore

mm (in) mm (in)

Motor input

Main fan Sub fan

W W

Fan diameter / Blade

Main fan Sub fan

Type Core dimensions

Width × Height × Thickness

Pressure range in which cap valve is open

0.5 — 1.5 (0.020 — 0.059) Wax pellet type 82 — 86°C (180 — 187°F) 91°C (196°F) 9.0 (0.354) or more 35 (1.38) 120 120 320 mm (12.6 in)/5 320 mm (12.6 in)/7 Down flow 687.4 × 340 × 16 (27.06 × 13.39 × 0.63)

mm (in)

Standard Positive presService sure side kPa (kg/cm2, psi) limit

93 — 123 (0.95 — 1.25, 14 — 18) 83 (0.85, 12)

Negative Standard pressure side

–1.0 — –4.9 (–0.01 — –0.05, –0.1 — –0.7)

Fins Reservoir tank

Corrugated fin type

Capacity

Coolant Water for dilution Cooling system protecting agent

2 (US qt, Imp qt)

Recommended materials SUBARU Super Coolant (Concentrated type) SUBARU Super Coolant (Diluted type)

0.45 (0.48, 0.40)

Item number

Alternative

— — K0670Y0001

Distilled water



Soft water or tap water

Cooling system conditioner

SOA345001



CO(H4DOTC)-2

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General Description COOLING

B: COMPONENT 1. WATER PUMP T1 T1

(7)

(8) (3)

(2) (9)

(1)

T3

(4) (5)

T2 (6)

T2 CO-02572

(1) (2) (3) (4)

Water pump ASSY Gasket Heater by-pass hose Thermostat

(5)

Gasket

(6) (7) (8) (9)

Thermostat cover Water by-pass pipe Clip Water pump sealing

CO(H4DOTC)-3

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 9 (0.9, 6.6) T3: First 12 (1.2, 8.9) Second 12 (1.2, 8.9)

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General Description COOLING

2. RADIATOR AND RADIATOR FAN

A

(8)

(5) T3

(6)

(15) (5) (14)

(10)

(7)

T4 (9) (13) (11) (4)

T2 (3) (19) T1

(2)

T2

A (12) T1 (5)

(16)

(18)

(1)

(5)

(17)

CO-02630

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Radiator lower cushion Radiator Radiator upper cushion Radiator upper bracket Clip Radiator inlet hose Engine coolant reservoir tank cap Over flow hose Engine coolant reservoir tank

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Radiator sub fan shroud Radiator main fan shroud Radiator main fan Radiator sub fan Main fan motor Sub fan motor Radiator outlet hose Radiator drain plug O-ring

CO(H4DOTC)-4

(19)

Radiator cap

Tightening torque:N·m (kgf-m, ft-lb) T1: 3.4 (0.3, 2.5) T2: 5 (0.5, 3.7) T3: 7.5 (0.8, 5.5) T4: 12 (1.2, 8.9)

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General Description COOLING

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. • Prepare a container and cloth to prevent scattering of engine coolant when performing work where engine coolant can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing engine coolant.

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General Description COOLING

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 499977100

DESCRIPTION CRANK PULLEY WRENCH

Used for removing and installing the crank pulley.

REMARKS

499977500

CAM SPROCKET WRENCH

Used for removing and installing the intake and exhaust cam sprocket.

1B022XU0

SUBARU SELECT MONITOR III KIT

Used for troubleshooting the electrical system.

ST-499977100

ST-499977500

ST1B022XU0

2. GENERAL TOOL TOOL NAME Circuit tester Radiator cap tester

REMARKS Used for measuring resistance and voltage. Used for checking radiator and radiator cap.

CO(H4DOTC)-6

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Radiator Fan System COOLING

2. Radiator Fan System A: WIRING DIAGRAM TO POWER SUPPLY CIRCUIT

MAIN FAN MOTOR

MB-7 M/B FUSE NO. 7 (B)

MAIN FAN RELAY 1

13

FB-39 F/B FUSE NO. 22 (IG)

A/C SUB RELAY HOLDER FAN RELAY B497

MAIN FAN RELAY 2

J/C

12

11

18

19

22

16

15

2

B473

10

21

20

FB-35 F/B FUSE NO. 26 (IG)

17

1

14

MB-6 M/B FUSE NO. 8 (B)

11

12

1

2

3

B482

B479

B135 ECM

SUB FAN MOTOR B473

B479

B482

1 2 3 4 5

B135

B497

1 2 8

3 4 5 6 7 9

12 10 11 13

16 14 15 17

1 2

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

18 19 20 21 22

A/C RELAY HOLDER

CO-02631

CO(H4DOTC)-7

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Radiator Fan System COOLING

B: INSPECTION Operating condition: Radiator fan operates depending on the radiator fan operation mode related to engine coolant temperature or the radiator fan operation mode related to A/C compressor load, whichever is higher as an operation mode. • Radiator fan operation mode related to engine coolant temperature

(A) (1)

(2)

(3)

(4)

(5)(6)

(B)

(7)

CO-02661

(A)

Radiator fan operation mode

(B)

Engine coolant temperature

(1) (2) (3)

High-Speed Low-Speed OFF

(4) (5) (6)

96°C (205°F) 97.5°C (207°F) 98°C (208°F)

CO(H4DOTC)-8

(7)

100°C (212°F)

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Radiator Fan System COOLING

• Radiator fan operation mode related to A/C compressor load

(A) (1)

(2)

(3)

(4)

(5)

(6)

(B)

(7)

CO-02662

(A)

Radiator fan operation mode

(B)

A/C compressor refrigerant pressure

(1) (2)

High-Speed Low-Speed

(4) (5)

(3)

OFF

(6)

0.8 MPa (8.16 kgf/cm2, 116 psi) 1.125 MPa (11.47 kgf/cm2, 163 psi) 1.25 MPa (12.75 kgf/cm2, 181 psi)

(7)

1.5 MPa (15.30 kgf/cm2, 218 psi)

DIAGNOSIS: Radiator main fan and radiator sub fans do not rotate under the above operating conditions. 1

Step Check CHECK OPERATION OF RADIATOR FAN. Do the radiator main fans and 1) Connect the delivery mode fuse. radiator sub fans rotate at low 2) Turn the ignition switch to ON. speed? 3) Using the Subaru Select Monitor, check the forced operation of the radiator fan relay. NOTE: • When performing a forced operation radiator fan relay check using the Subaru Select Monitor, the radiator main fan and radiator sub fan will repeat low speed revolution → high speed revolution → OFF in this order. • Subaru Select Monitor For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

CO(H4DOTC)-9

Yes Go to step 2.

No Go to step 3.

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Radiator Fan System COOLING

2

3

4

5

6

7

8

Step CHECK OPERATION OF RADIATOR FAN. 1) Connect the delivery mode fuse. 2) Turn the ignition switch to ON. 3) Perform the compulsory operation check for the radiator fan relay using Subaru Select Monitor. NOTE: • When performing a forced operation radiator fan relay check using the Subaru Select Monitor, the radiator main fan and radiator sub fan will repeat low speed revolution → high speed revolution → OFF in this order. • Subaru Select Monitor For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. CHECK POWER SUPPLY TO SUB FAN RELAY. 1) Turn the ignition switch to OFF. 2) Remove the sub fan relay from A/C relay holder. 3) Measure the voltage between sub fan relay connector and chassis ground. Connector & terminal (B497) No. 10 (+) — Chassis ground (–): CHECK POWER SUPPLY TO SUB FAN RELAY. 1) Turn the ignition switch to ON. 2) Measure the voltage between sub fan relay connector and chassis ground. Connector & terminal (B497) No. 13 (+) — Chassis ground (–): CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 7. 3) Check the condition of fuse. CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 22. 3) Check the condition of fuse. CHECK SUB FAN RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between sub fan relay terminals. Terminals No. 10 — No. 11: CHECK SUB FAN RELAY. 1) Connect the battery to terminals No. 12 and No. 13 of the sub fan relay. 2) Measure the resistance between sub fan relay terminals. Terminals No. 10 — No. 11:

Check Yes Do the radiator main fans and Radiator main fan radiator sub fans rotate at high system is normal. speed?

No Go to step 27.

Is the voltage 10 V or more?

Go to step 4.

Go to step 5.

Is the voltage 10 V or more?

Go to step 7.

Go to step 6.

Is the fuse blown out?

Replace the fuse.

Repair the power supply line.

Is the fuse blown out?

Replace the fuse.

Repair the power supply line.

Is the resistance 1 MΩ or more?

Go to step 8.

Replace the sub fan relay.

Is the resistance less than 1 Ω? Go to step 9.

Replace the sub fan relay.

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Radiator Fan System COOLING

9

10

11

12

13

14

15

16

17

Step CHECK HARNESS BETWEEN SUB FAN RELAY CONNECTOR AND SUB FAN MOTOR CONNECTOR. 1) Disconnect the connector from the sub fan motor. 2) Measure the resistance of harness between sub fan relay connector and sub fan motor connector. Connector & terminal (B482) No. 1 — (B497) No. 11: CHECK HARNESS BETWEEN SUB FAN MOTOR CONNECTOR AND MAIN FAN RELAY 2 CONNECTOR. 1) Remove the main fan relay 2 from A/C relay holder. 2) Measure the resistance of harness between sub fan motor connector and main fan relay 2 connector. Connector & terminal (B482) No. 2 — (B497) No. 18: CHECK FOR POOR CONTACT. Check poor contact of sub fan motor connector.

Check Yes Is the resistance less than 1 Ω? Go to step 10.

No Repair the open circuit of harness between sub fan relay connector and sub fan motor connector.

Is the resistance less than 1 Ω? Go to step 11.

Repair the open circuit of the harness between sub fan motor connector and main fan relay 2 connector.

Is there poor contact of the sub Repair the poor fan motor connector? contact of sub fan motor connector. CHECK SUB FAN MOTOR. Does the radiator sub fan Go to step 13. Connect the battery positive (+) terminal to ter- rotate? minal No. 1 of the sub fan motor, and the ground (–) terminal to terminal No. 2. CHECK MAIN FAN RELAY 2. Is the resistance less than 1 Ω? Go to step 14. Measure the resistance between main fan relay 2 terminals. Terminals No. 21 — No. 18: CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Ω? Go to step 15. RELAY 2 CONNECTOR AND MAIN FAN MOTOR CONNECTOR. 1) Disconnect the connector from the main fan motor. 2) Measure the resistance of the harness between main fan relay 2 connector and main fan motor connector. Connector & terminal (B473) No. 1 — (B497) No. 21: CHECK MAIN FAN MOTOR AND GROUND Is the resistance less than 5 Ω? Go to step 16. CIRCUIT. Measure the resistance between main fan motor connector and chassis ground. Connector & terminal (B473) No. 2 — Chassis ground:

CHECK FOR POOR CONTACT. Check poor contact of main fan motor connector. CHECK MAIN FAN MOTOR. Connect the battery positive (+) terminal to terminal No. 1 of the main fan motor, and the ground (–) terminal to terminal No. 2.

Is there poor contact of the main fan motor connector? Does the radiator main fan rotate?

CO(H4DOTC)-11

Go to step 12.

Replace the sub fan motor.

Replace the main fan relay 2.

Repair the open circuit of the harness between main fan relay 2 connector and main fan motor connector.

Repair the open circuit of the harness between main fan motor connector and chassis ground or poor contact of the joint connector. Go to step 17.

Repair the poor contact of main fan motor connector. Go to step 18. Replace the main fan motor.

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Radiator Fan System COOLING

18

19

20

21

22

23

24

25

26

Step Check Yes CHECK HARNESS BETWEEN SUB FAN RE- Is the resistance less than 1 Ω? Go to step 19. LAY CONNECTOR AND ECM. 1) Disconnect the connectors from ECM. 2) Measure the resistance between the sub fan relay connector and ECM connector. Connector & terminal (B135) No. 11 — (B497) No. 12: CHECK FOR POOR CONTACT. Is there poor contact of ECM Repair the poor Check for poor contact of ECM connector. connector? contact of ECM connector.

CHECK MAIN FAN RELAY 1. 1) Turn the ignition switch to OFF. 2) Remove the main fan relay 1 from A/C relay holder. 3) Measure the resistance between main fan relay 1 terminals. Terminals No. 14 — No. 15: CHECK MAIN FAN RELAY 1. 1) Connect terminals No. 17 and No. 16 of the main fan relay 1 to the battery. 2) Measure the resistance between main fan relay 1 terminals. Terminals No. 14 — No. 15: CHECK HARNESS BETWEEN MAIN FAN RELAY 1 CONNECTOR AND MAIN FAN MOTOR CONNECTOR. 1) Disconnect the connector from the main fan motor. 2) Measure the resistance of the harness between main fan relay 1 connector and main fan motor connector. Connector & terminal (B473) No. 1 — (B497) No. 15: CHECK HARNESS BETWEEN MAIN FAN RELAY 1 CONNECTOR AND ECM. 1) Disconnect the connectors from ECM. 2) Measure the resistance between main fan relay 1 connector and ECM connector. Connector & terminal (B135) No. 12 — (B497) No. 16: CHECK HARNESS BETWEEN MAIN FAN RELAY 2 CONNECTOR AND ECM. Measure the resistance between main fan relay 2 connector and ECM connector. Connector & terminal (B135) No. 12 — (B497) No. 22: CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 8 and 26. 3) Check the condition of fuse. CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Is the resistance 1 MΩ or more?

Go to step 21.

No Repair the open circuit of harness between sub fan relay connector and ECM.

Check the DTC. Repair the trouble cause. Replace the main fan relay 1.

Is the resistance less than 1 Ω? Go to step 22.

Replace the main fan relay 1.

Is the resistance less than 1 Ω? Go to step 23.

Repair the open circuit of the harness between main fan relay 1 connector and main fan motor connector.

Is the resistance less than 1 Ω? Go to step 24.

Repair the open circuit of the harness between main fan relay 1 connector and ECM.

Is the resistance less than 1 Ω? Go to step 25.

Is the fuse blown out?

Replace the fuse.

Repair the open circuit of the harness between main fan relay 2 connector and ECM. Go to step 26.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

Repair the power supply circuit to the main fuse box.

CO(H4DOTC)-12

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Radiator Fan System COOLING

27

28

29

30

31

Step CHECK OPERATION OF RADIATOR FAN. If the both fans do not rotate at high speed in the condition of step 2, check whether the radiator sub fan is rotating. CHECK GROUND CIRCUIT OF MAIN FAN RELAY 2 CONNECTOR. 1) Remove the main fan relay 2 from A/C relay holder. 2) Measure the resistance between main fan relay 2 connector and chassis ground. Connector & terminal (B497) No. 19 — Chassis ground: CHECK POWER SUPPLY TO MAIN FAN RELAY 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between main fan relay 2 connector and chassis ground. Connector & terminal (B497) No. 20 (+) — Chassis ground (–): CHECK MAIN FAN RELAY 2. 1) Turn the ignition switch to OFF. 2) Remove the main fan relay 2. 3) Measure the resistance between main fan relay 2 terminals. Terminals No. 18 — No. 19: CHECK MAIN FAN RELAY 2. 1) Connect the battery to terminals No. 20 and No. 22 of the main fan relay 2. 2) Measure the resistance between main fan relay 2 terminals. Terminals No. 18 — No. 19:

Check Does the radiator sub fan rotate?

Yes Go to step 20.

Is the resistance less than 1 Ω? Go to step 29.

No Go to step 28.

Repair the open circuit of the harness between main fan relay 2 and chassis ground or poor contact of the joint connector. Repair the power supply line.

Is the voltage 10 V or more?

Go to step 30.

Is the resistance 1 MΩ or more?

Go to step 31.

Replace the main fan relay 2.

Is the resistance less than 1 Ω? Go to step 23.

Replace the main fan relay 2.

CO(H4DOTC)-13

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Engine Coolant COOLING

3. Engine Coolant A: REPLACEMENT 1. DRAINING OF ENGINE COOLANT 1) Lift up the vehicle. 2) Remove the under cover. 3) Remove the drain plug to drain engine coolant into container.

NOTE: The SUBARU Super Coolant is especially made for SUBARU engine, which has an aluminum cylinder block, and contains anti-freeze and anti-rust agents. Always use SUBARU Super Coolant, since other coolant may cause corrosion. 3) Fill engine coolant into the reservoir tank up to “FULL” level.

NOTE: Remove the radiator cap so that engine coolant will drain faster. FULL LOW CO-02633

CO-02632

4) Install the drain plug. 5) Install the under cover.

2. FILLING OF ENGINE COOLANT 1) Pour cooling system conditioner from the filler neck of the radiator.

Cooling system protecting agent: Refer to “SPECIFICATION” for cooling system protecting agent. 2) Pour engine coolant into the radiator up to the filler neck position. Recommended engine coolant: Refer to “SPECIFICATION” for recommended engine coolant. Engine coolant level: Refer to “SPECIFICATION” for engine coolant level. Engine coolant concentration: Refer to “ADJUSTMENT” for the recommended engine coolant concentration.

4) Close the radiator cap and start the engine. Race 5 to 6 times at 3,000 rpm or less, then stop the engine. (Complete this operation within 40 seconds.) 5) Wait for one minute after the engine stops, and open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position. 6) Perform the procedures 4) and 5) again. 7) Attach the radiator cap and reservoir tank cap properly. 8) Start the engine and operate the heater at maximum hot position and the blower speed setting to “LO”. 9) Run the engine at 2,000 rpm or less until radiator fan starts and stops. NOTE: Be careful with the engine coolant temperature gauge to prevent overheating. 10) Stop the engine and wait until the engine coolant temperature lowers to 30°C (86°F) or less. 11) Open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position and reservoir tank to the “FULL” level. 12) Attach the radiator cap and reservoir tank cap properly. 13) Set the heater setting to maximum hot position and the blower speed setting to “LO” and start the engine. Perform racing at 3,000 rpm or less. If the flowing sound is heard from heater core, repeat the procedures from step 9).

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Engine Coolant COOLING

B: ADJUSTMENT 1. PROCEDURE TO ADJUST THE SUBARU SUPER COOLANT CONCENTRATION CAUTION: SUBARU Super Coolant concentration must be used from 50 to 60% to assure the best performance of the anti-freeze and anti-rust agents. To adjust the concentration of SUBARU Super Coolant according to temperature, find the proper SUBARU Super Coolant concentration in the table, and add diluting water to the SUBARU Super Coolant (concentrated type) until it reaches the proper dilution. Relationship of SUBARU Super Coolant concentration and freezing temperature SUBARU Super Coolant concentration 50% 55% Freezing temperature –36°C (–33°F) –41°C (–42°F)

60% –50°C (–58°F)

Recommended engine coolant and water for dilution: Refer to “SPECIFICATION” for the recommended engine coolant and diluting water.

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Water Pump COOLING

4. Water Pump

14) Remove the water pump.

A: REMOVAL 1) Remove the collector cover. 2) Remove the radiator. 3) Remove the V-belts. 4) Remove the crank pulley. 5) Remove the timing belt cover. 6) Remove the timing belt. 7) Remove the automatic belt tension adjuster (A). 8) Remove the belt idler (B). 9) Remove the belt idler No. 2 (C).

(A) (B) CO-02608

B: INSTALLATION 1) Install the water pump onto cylinder block LH.

(C) CO-00023

10) Remove the cam sprocket LH. 11) Remove the belt cover No. 2 LH.

NOTE: • Use a new gasket. • Use new water pump sealing. • When installing the water pump, tighten bolts in two stages in alphabetical order as shown in the figure.

CO-02577

12) Remove the tensioner bracket.

CO-00025

13) Disconnect the hose from water pump.

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Water Pump COOLING

Tightening torque: First: 12 N·m (1.2 kgf-m, 8.9 ft-lb) Second: 12 N·m (1.2 kgf-m, 8.9 ft-lb)

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

(B) (C) (A) CO-02577

(D)

(E)

5) Install the cam sprocket LH. 6) Install the belt idler No. 2 (C).

(F)

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb) 7) Install the belt idler (B).

CO-02578

2) Install the hose to water pump. 3) Install the tensioner bracket.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) 8) Install the automatic belt tension adjuster (A) with the tension rod held by a pin.

Tightening torque: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

(A) (B)

(C) CO-00023

CO-00025

4) Install the belt cover No. 2 LH.

9) Install the timing belt. 10) Install the timing belt cover. 11) Install the crank pulley. 12) Install the V-belts. 13) Install the radiator. 14) Install the collector cover.

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Water Pump COOLING

C: INSPECTION 1) Check the water pump bearing for smooth rotation. 2) Check the water pump pulley for abnormalities. 3) Make sure the impeller is not abnormally deformed or damaged. 4) Inspect the clearance between impeller and pump case.

Clearance between impeller and pump case: Standard 0.5 — 1.5 mm (0.020 — 0.059 in)

CO-00293

5) After water pump installation, check pulley shaft for engine coolant leaks or noise. If leaks or noise are noted, replace the water pump assembly.

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Thermostat COOLING

5. Thermostat

B: INSTALLATION

A: REMOVAL

1) Install a gasket to thermostat.

1) Lift up the vehicle. 2) Remove the under cover. 3) Drain engine coolant. 4) Disconnect the radiator outlet hose from thermostat cover.

NOTE: Install the parts with the jiggle pin facing upside.

NOTE: Use a new gasket. 2) Install the thermostat and thermostat cover.

Tightening torque: 9 N·m (0.9 kgf-m, 6.6 ft-lb)

(D)

CO-02579

5) Remove the thermostat cover, and then remove the gasket and thermostat.

(C) T

(B) (A)

T

CO-02581

(A) (B) (C) (D)

(C) (B) (A)

CO-02580

Thermostat cover Gasket Thermostat Jiggle pin

3) Connect the radiator outlet hose to thermostat cover. 4) Install the under cover. 5) Lower the vehicle. 6) Fill engine coolant.

(A) Thermostat cover (B) Gasket (C) Thermostat

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Thermostat COOLING

C: INSPECTION 1) Check that the thermostat does not have deformation, cracks or damage. 2) Check that the thermostat valve closes completely at an ambient temperature. 3) Immerse the thermostat and a thermometer in water. Raise water temperature gradually, and check the temperature and valve lift when the valve begins to open and when the valve is fully opened. Replace the thermostat if faulty. NOTE: • During the test, agitate the water for even temperature distribution. • Leave the thermostat in the boiling water for five minutes or more before measuring the valve lift. • Hold the thermostat with a wire or the like to avoid contacting the container.

Starting temperature to open: 82 — 86°C (180 — 187°F) Full open temperature: 91°C (196°F) Total valve lift: 9.0 mm (0.354 in) or more

(A)

(B)

CO-02420

(A) Thermometer (B) Thermostat

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Radiator COOLING

6. Radiator

10) Disconnect the connectors of main fan motor connector (A) and sub fan motor connector (B).

A: REMOVAL CAUTION: The radiator is pressurized when the engine and radiator are hot. Wait until engine and radiator cools down before working on the radiator. 1) Remove the collector cover. 2) Disconnect the ground cable from battery.

(A) CO-02634

(B)

IG-02107

3) Lift up the vehicle. 4) Remove the under cover. 5) Drain engine coolant. 6) Disconnect the radiator outlet hose from thermostat cover.

CO-02635

11) Disconnect the radiator inlet hose from the water tank pipe.

CO-02636

12) Remove the grille bracket. CO-02579

7) Lower the vehicle. 8) Remove the air intake duct. 9) Remove the reservoir tank.

NOTE: Remove ten clips when removing the grille bracket.

CO-02637

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Radiator COOLING

Tightening torque: 12 N·m (1.2 kgf-m, 8.9 ft-lb)

13) Remove the radiator upper brackets.

CO-02638

14) Lift the radiator up and remove the radiator from vehicle. 15) Remove the radiator lower cushion from the vehicle body.

CO-02638

4) Attach the grille bracket.

CO-02637 CO-02639

5) Connect the radiator inlet hose.

B: INSTALLATION 1) Install the radiator lower cushion to the vehicle body.

CO-02636

CO-02639

2) Install the radiator to the vehicle. NOTE: Insert the pin on the lower side of radiator into the radiator lower cushion. 3) Install the radiator upper brackets.

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Radiator COOLING

6) Connect the connectors of main fan motor connector (A) and sub fan motor connector (B).

14) Fill engine coolant. 15) Install the collector cover.

C: INSPECTION

(A) CO-02634

1) Check that the radiator does not have deformation, cracks or damage. 2) Check that the hose has no cracks, damage or loose part. 3) Remove the radiator cap, fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.

(B)

CO-02635

7) Install the reservoir tank.

8) Install the air intake duct. 9) Lift up the vehicle. 10) Connect the radiator outlet hose.

CO-02640

4) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi) to the radiator and check the following points: • Leakage from the radiator or its vicinity • Leakage from the hose or its connections CAUTION: • Engine should be turned off. • Wipe engine coolant from check points in advance. • Be careful of the spurt of engine coolant when removing the radiator cap tester. • Be careful not to deform the filler neck of radiator when installing and removing the radiator cap tester.

CO-02579

11) Install the under cover. 12) Lower the vehicle. 13) Connect the ground cable to battery.

IG-02107

CO(H4DOTC)-23

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Radiator Cap COOLING

7. Radiator Cap A: INSPECTION 1) Check that the radiator cap does not have deformation, cracks or damage. 2) Attach the radiator cap tester to radiator cap.

CO-00044

3) Increase pressure until the radiator cap tester gauge needle stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 — 6 seconds. Replace the radiator cap if its valve opens at less than the service limit.

Standard: 93 — 123 kPa (0.95 — 1.25 kgf/cm2, 14 — 18 psi) Service limit: 83 kPa (0.85 kgf/cm2, 12 psi) CAUTION: Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect.

CO(H4DOTC)-24

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Radiator Main Fan and Fan Motor COOLING

8. Radiator Main Fan and Fan Motor

B: INSTALLATION

A: REMOVAL

CAUTION: Confirm that the radiator hose is securely connected.

1) Remove the collector cover. 2) Disconnect the ground cable from battery.

Install in the reverse order of removal.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

IG-02107

3) Remove the reservoir tank. 4) Disconnect the main fan motor connector (A).

CO-02641

C: DISASSEMBLY 1) Remove the main fan motor connector and main fan motor harness from the radiator main fan shroud. 2) Remove the radiator main fan from the main fan motor.

(A) CO-02634

5) Remove the bolts that secure the radiator main fan motor assembly. CO-02642

3) Remove the main fan motor from the radiator main fan shroud.

CO-02641

6) Remove the radiator main fan motor assembly from the upper side of the vehicle. CO-02643

CO(H4DOTC)-25

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Radiator Main Fan and Fan Motor COOLING

D: ASSEMBLY Assemble in the reverse order of disassembly.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

CO-02643

Tightening torque: 3.4 N·m (0.3 kgf-m, 2.5 ft-lb)

CO-02642

E: INSPECTION Check that the radiator main fan, radiator main fan shroud and main fan motor do not have deformation, cracks or damage.

CO(H4DOTC)-26

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Radiator Sub Fan and Fan Motor COOLING

9. Radiator Sub Fan and Fan Motor

B: INSTALLATION

A: REMOVAL

CAUTION: Confirm that the radiator hose is securely connected.

1) Remove the collector cover. 2) Disconnect the ground cable from battery.

Install in the reverse order of removal.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

IG-02107

3) Remove the air intake duct. 4) Disconnect the sub fan motor connector (B).

CO-02644

C: DISASSEMBLY 1) Remove the sub fan motor connector and sub fan motor harness from the radiator sub fan shroud. 2) Remove the radiator sub fan from the sub fan motor.

(B)

CO-02635

5) Remove the bolts that secure the radiator sub fan motor assembly. CO-02645

3) Remove the sub fan motor from the radiator sub fan shroud.

CO-02644

6) Remove the radiator sub fan motor assembly from the upper side of the vehicle. CO-02646

CO(H4DOTC)-27

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Radiator Sub Fan and Fan Motor COOLING

D: ASSEMBLY Assemble in the reverse order of disassembly.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

CO-02646

Tightening torque: 3.4 N·m (0.3 kgf-m, 2.5 ft-lb)

CO-02645

E: INSPECTION Check that the radiator sub fan, radiator sub fan shroud and sub fan motor do not have deformation, cracks or damage.

CO(H4DOTC)-28

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Reservoir Tank COOLING

10.Reservoir Tank A: REMOVAL 1) Pull out the over flow hose (A). 2) Pull out the reservoir tank to the arrow direction while pushing the claw (B). (B)

(A) CO-02647

B: INSTALLATION Install in the reverse order of removal.

C: INSPECTION 1) Check that the reservoir tank does not have deformation, cracks or damage. 2) Check the over flow hose for cracks or damage. 3) Make sure the engine coolant level is between “FULL” and “LOW”.

FULL LOW CO-02633

CO(H4DOTC)-29

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Engine Cooling System Trouble in General COOLING

11.Engine Cooling System Trouble in General A: INSPECTION Trouble

Possible cause a. Insufficient engine coolant b. Loose timing belt c. Oil on timing belt d. Malfunction of thermostat e. Malfunction of water pump f. Clogged engine coolant passage g. Improper ignition timing

Over-heating

h. Clogged or leaking radiator i. Defective radiator fan j. Improper engine oil in engine coolant k. Air/fuel mixture ratio too lean l. Excessive back pressure in exhaust system m. Insufficient clearance between piston and cylinder n. Slipping clutch o. Dragging brake

Over-cooling

Noise

Replenish engine coolant, inspect for leakage, and repair it if necessary. Repair or replace timing belt tensioner. Replace. Replace. Replace. Clean. Inspect and repair ignition control system. Clean, repair or replace. Replace. Replace the engine coolant. If ineffective, check, repair or replace engine components. Inspect and repair the fuel injection system. Clean or replace. Adjust or replace. Repair or replace. Adjust.

p. Defective radiator fan

Inspect the radiator fan relay, engine coolant temperature sensor or fan motor and replace them.

a. Ambient temperature extremely low b. Defective thermostat

Partly cover radiator front area. Replace.

a. Loosened or damaged connecting units on hoses

Repair or replace.

b. Leakage from water pump c. Leakage from water pipe Engine coolant leaks

Corrective action

d. Leakage around cylinder head gasket

Replace. Repair or replace. Retighten cylinder head bolts or replace cylinder head gasket.

e. Damaged or cracked cylinder head and cylinder block

Repair or replace.

f. Damaged or cracked thermostat cover g. Leakage from radiator a. Timing belt problem b. Defective radiator fan c. Defective water pump bearing d. Defective water pump mechanical seal

Repair or replace. Repair or replace. Replace. Replace. Replace water pump. Replace water pump.

CO(H4DOTC)-30

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LUBRICATION

LU(H4DOTC) 1.

Page General Description ...................................................................................2

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General Description LUBRICATION

1. General Description A: SPECIFICATION Specifications for the turbo model are included in the LU (H4SO) section.

LU(H4DOTC)-2

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SPEED CONTROL SYSTEMS

SP(H4DOTC) 1.

Page General Description ...................................................................................2

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General Description SPEED CONTROL SYSTEMS

1. General Description A: SPECIFICATION Specifications for the turbo model are the same as the non-turbo model.

SP(H4DOTC)-2

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IGNITION

IG(H4DOTC) 1. 2. 3.

Page General Description ...................................................................................2 Spark Plug ..................................................................................................4 Ignition Coil ................................................................................................6

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General Description IGNITION

1. General Description A: SPECIFICATION Item Type Ignition system Manufacturer Manufacturer and type Thread size (diameter, pitch, length) mm Spark plug gap mm (in) Standard

Ignition coil

Spark plug

Electrode

SPECIFICATION FK0368 Independent ignition coil Diamond Electric NGK: SILFR6B8 14,1.25,26.5 0.7 — 0.8 (0.028 — 0.031) Iridium

B: COMPONENT

T1

T2 (2) (1)

T2 (1) (2)

T1

IG-02098

(1)

Spark plug

(2)

Ignition coil

IG(H4DOTC)-2

Tightening torque:N·m (kgf-m, ft-lb) T1: 16 (1.6, 11.8) T2: 21 (2.1, 15.5)

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General Description IGNITION

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.

IG(H4DOTC)-3

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Spark Plug IGNITION

2. Spark Plug

NOTE: Turn #4 ignition coil by 180 degrees to remove it.

A: REMOVAL Spark plug: Refer to “SPECIFICATION” for the spark plug.

1. RH SIDE 1) Disconnect the ground cable from battery. IG-02100

4) Remove the spark plug with a spark plug socket.

B: INSTALLATION 1. RH SIDE Install in the reverse order of removal. IG-02107

Tightening torque (Spark plug): 21 N·m (2.1 kgf-m, 15.5 ft-lb)

2) Remove the air cleaner case. 3) Disconnect the connector from ignition coil. 4) Remove the ignition coil.

Tightening torque (Ignition coil): 16 N·m (1.6 kgf-m, 11.8 ft-lb)

NOTE: Turn #3 ignition coil by 180 degrees to remove it.

Install in the reverse order of removal.

2. LH SIDE Tightening torque (Spark plug): 21 N·m (2.1 kgf-m, 15.5 ft-lb) Tightening torque (Ignition coil): 16 N·m (1.6 kgf-m, 11.8 ft-lb)

C: INSPECTION 1) Check the spark plug for abnormalities. If defective, replace the spark plug. (C) IG-02099

5) Remove the spark plug with a spark plug socket.

2. LH SIDE 1) Remove the battery. 2) Disconnect the connector from ignition coil. 3) Remove the ignition coil.

(A) (B)

IG-02094

(A) Terminal damage (B) Crack or damage in insulator (C) Damaged gasket

2) Check the spark plug electrode and condition of the insulator. If abnormal, check and repair the cause and replace the spark plug.

IG(H4DOTC)-4

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Spark Plug IGNITION

(1) Normal: Brown to grayish-tan deposits and slight electrode wear indicate correct spark plug heat range.

(4) Overheating: White or light gray insulator with black or brown spots and bluish burnt electrodes indicate engine overheating, wrong selection of fuel, or loose spark plugs.

IG-00011

(2) Carbon fouled: Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in the city, weak ignition, too rich fuel mixture, etc.

IG-00014

3) Using a nylon brush, etc., clean and remove the carbon or oxide deposits from the spark plug. If deposits are too stubborn, replace the spark plugs. After cleaning the spark plugs, check the spark plug gap “L” using a gap gauge. If it is not within the standard, replace the spark plug. NOTE: • Never use a plug cleaner. • Do not use a metal brush as it may damage the electrode area.

IG-00012

Spark plug gap L: Standard 0.7 — 0.8 mm (0.028 — 0.031 in)

(3) Oil fouled: Wet black deposits show oil entrance into combustion chamber through worn piston rings or increased clearance between valve guides and valve stems.

L

IG-02095

IG-00013

IG(H4DOTC)-5

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Ignition Coil IGNITION

3. Ignition Coil A: REMOVAL Direct ignition type has been adopted. Refer to “Spark Plug”, “REMOVAL” for removal procedures.

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

C: INSPECTION For inspection procedure, refer to “Diagnostics for Engine Starting Failure”.

IG(H4DOTC)-6

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STARTING/CHARGING SYSTEMS

SC(H4DOTC) 1.

Page General Description ...................................................................................2

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General Description STARTING/CHARGING SYSTEMS

1. General Description A: SPECIFICATION Specifications for the turbo model are included in the SC(H4SO) section.

SC(H4DOTC)-2

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ENGINE (DIAGNOSTICS)

EN(H4DOTC)(diag) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Page Basic Diagnostic Procedure .......................................................................2 Check List for Interview ..............................................................................4 General Description ...................................................................................6 Electrical Component Location ..................................................................9 Engine Control Module (ECM) I/O Signal ................................................19 Engine Condition Data .............................................................................30 Data Link Connector ................................................................................31 General Scan Tool ...................................................................................32 Subaru Select Monitor ..............................................................................37 Read Diagnostic Trouble Code (DTC) .....................................................43 Inspection Mode .......................................................................................44 Drive Cycle ...............................................................................................49 Clear Memory Mode .................................................................................55 System Operation Check Mode ...............................................................56 Malfunction Indicator Light .......................................................................57 Diagnostics for Engine Starting Failure ....................................................67 List of Diagnostic Trouble Code (DTC) ....................................................78 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................86 General Diagnostic Table .......................................................................337

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Basic Diagnostic Procedure ENGINE (DIAGNOSTICS)

1. Basic Diagnostic Procedure A: PROCEDURE 1. ENGINE 1

Step Check CHECK ENGINE START FAILURE. Does the engine start? 1) Ask the customer when and how the trouble occurred using the interview check list. 2) Start the engine.

2

CHECK ILLUMINATION OF MALFUNCTION Does the malfunction indicator light illuminate? INDICATOR LIGHT.

3

CHECK COMMUNICATION STATUS. Does Subaru select monitor or 1) Turn the ignition switch to OFF. general scan tool communicate 2) Connect the Subaru Select Monitor or gen- with vehicle normally? eral scan tool to data link connector. 3) Turn the ignition switch to ON, and run the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed procedures, refer to “Subaru Select Monitor”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

4

CHECK DTC. Is DTC displayed on Subaru Read DTC using Subaru Select Monitor or gen- Select Monitor or general scan eral scan tool. tool? NOTE: • Subaru Select Monitor Refer to “Read Diagnostic Trouble Code” for detailed operation procedure. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H4DOTC)(diag)-2

Yes Go to step 2.

No Inspection using “Diagnostics for Engine Start Failure”. Go to step 3. Inspection using “General Diagnostic Table”. Go to step 4. Inspection using LAN system “Diagnostic Procedure with Diagnostic Trouble Code (DTC)”. Record the DTC. Repair the related Repair the trouble parts. cause. Go function indicator to step 5. light illuminates, perform the diagnosis of malfunction indicator light circuit or combination meter.

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Basic Diagnostic Procedure ENGINE (DIAGNOSTICS)

5

6

Step CHECK FREEZE FRAME DATA. Check the freeze frame data using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed procedures, refer to “Subaru Select Monitor”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. PERFORM DIAGNOSIS. 1) Perform the Clear Memory Mode. 2) Perform the Inspection Mode or drive cycle.

Check Yes No Is freeze frame data displayed Record the freeze Go to step 6. on Subaru Select Monitor or frame data. Repair general scan tool? the cause of fault, and go to the next step. Go to step 6.

Inspect using Is DTC displayed on Subaru Finish the diagnoSelect Monitor or general scan “Diagnostic Proce- sis. dure with Diagnostool? tic Trouble Code (DTC)”.

EN(H4DOTC)(diag)-3

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Check List for Interview ENGINE (DIAGNOSTICS)

2. Check List for Interview A: CHECK 1. CHECK LIST NO. 1 Check the following item when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer’s name Date of purchase Date of repair V.I.N. Weather

Engine No. Fuel brand

Fine Cloudy Rainy Snowy Various/Others:

Ambient air temperature

Place

Engine temperature

Engine speed Vehicle speed Driving conditions

Headlight Blower A/C compressor Radiator fan Front wiper Rear wiper

km miles

Odometer reading

°C (

°F)

Hot Warm Cool Cold Highway Suburbs Inner city Uphill Downhill Rough road Others: Cold Warming-up After warming-up Any temperature Others: rpm km/h (MPH) Not affected At starting While idling At racing While accelerating While cruising While decelerating While turning (RH/LH) ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF

Rear defogger Audio CD/Cassette Car phone Wireless device

EN(H4DOTC)(diag)-4

ON/ ON/ ON/ ON/ ON/

OFF OFF OFF OFF OFF

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Check List for Interview ENGINE (DIAGNOSTICS)

2. CHECK LIST NO. 2 Check the following item about the vehicle’s state when malfunction indicator light illuminates. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators turn on. Yes / No Low fuel warning light Charge indicator light Engine coolant temperature indicator light Oil pressure warning light ATF temperature indicator light or SPORT indicator light Drivers control center differential indicator light ABS warning light VDC warning light Cruise indicator light SI-CRUISE warning light Immobilizer indicator light STEERING indicator light Glow indicator light Sedimentor warning light Others: b) Fuel level • Lack of gasoline: Yes / No • Indicator position of fuel gauge: • Experienced running out of fuel: Yes / No c) Intentional connecting or disconnecting of harness connectors or spark plug cords: • What: d) Intentional connecting or disconnecting of hoses: Yes / No • What: e) Installing of parts other than genuine parts: Yes / No • What: • Where: f) Occurrence of noise: Yes / No • From where: • What kind: g) Occurrence of smell: Yes / No • From where: • What kind: h) Intrusion of water into engine compartment or passenger compartment: i) Troubles occurred Engine does not start. Engine stalls during idling. Engine stalls while driving. Engine speed decreases. Engine speed does not decrease. Rough idling Poor acceleration Back fire After fire Does not shift. Excessive shift shock

Yes /

EN(H4DOTC)(diag)-5

Yes /

No

No

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General Description ENGINE (DIAGNOSTICS)

3. General Description

7) Use ECM mounting stud bolts at the body side grounding point when measuring voltage and resistance inside the passenger compartment.

A: CAUTION 1) Airbag system wiring harness is routed near the ECM, main relay and fuel pump relay. CAUTION: • Do not use electrical test equipment on the airbag system circuit. • Be careful not to damage the airbag system wiring harness when servicing the ECM, TCM, main relay and fuel pump relay. 2) Never connect the battery in reverse polarity. Doing so will damage the ECM instantly, and other parts will also be damaged. 3) Do not disconnect the battery terminals while the engine is running. A large counter electromotive force will be generated in the generator, and this voltage may damage electronic parts such as ECM etc. 4) Before disconnecting the connectors of each sensor and ECM, be sure to turn the ignition switch to OFF. Perform the Clear Memory Mode after connecting the connectors. 5) When measuring the voltage or resistance of individual sensor or all electrical control modules, use a tapered pin with a diameter of less than 0.6 mm (0.024 in). Do not insert the pin 4 mm (0.16 in) or more into the part. CAUTION: When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system. NOTE: When replacing the ECM of the models with Immobilizer, immobilizer system must be registered. To do so, all ignition keys and ID cards need to be prepared. For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. 6) Take care not to allow water to get into the connectors when servicing or washing the vehicle in rainy weather. Avoid exposure to water even if the connectors are waterproof.

(A)

EN-07713

(A) Stud bolt

8) Use the engine ground terminal or engine assembly as the grounding point to chassis when measuring the voltage and resistance in engine compartment.

EN-07823

9) Every MFI-related part is a precision part. Do not drop them. 10) Observe the following cautions when installing a radio in vehicle. CAUTION: • The antenna must be kept as far apart as possible from control module. (ECM is installed at the back of the glove box.) • The antenna feeder must be placed as far apart as possible from the ECM and engine control system harness. • Carefully adjust the antenna for correct matching. • When mounting a large power type radio, pay special attention to the three items mentioned above. • Incorrect installation of the radio may affect the operation of ECM. 11) When disconnecting the fuel hose, release the fuel pressure.

EN(H4DOTC)(diag)-6

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General Description ENGINE (DIAGNOSTICS)

12) For the model with ABS, the ABS warning light may illuminate when performing driving test with jacked-up or lifted-up condition, but this is not a system malfunction. The reason for this is the speed difference between the front and rear wheels. When engine control system diagnosis is finished, perform the VDC memory clearance procedure of self-diagnosis function.

B: INSPECTION Before performing diagnostics, check the following item which might affect engine problems.

1. BATTERY 1) Measure the battery voltage and specific gravity of the electrolyte.

• The OBD system stores freeze frame engine condition data (engine load, engine coolant temperature, fuel trim, engine speed and vehicle speed, etc.) into on-board computer when it detects a malfunction. • Freeze frame engine condition data are stored until the DTCs are cleared. However when such malfunctions as fuel trim fault and misfire are detected with the freeze frame engine condition data stored, they are rewritten into those related to the fuel trim fault and misfire. • When the malfunction does not occur again for three consecutive driving cycles, malfunction indicator light is turned off, but DTC remains at onboard computer. • When performing diagnosis, connect the Subaru Select Monitor or general scan tool to the vehicle.

Standard voltage: 12 V Specific gravity: 1.260 or more 2) Check the condition of the main and other fuses, and harnesses and connectors. Also check for proper grounding.

2. ENGINE GROUND Make sure that the engine ground terminal is properly connected to the engine.

EN-07823

C: NOTE • The on-board diagnostic (OBD) system detects and indicates a fault in various inputs and outputs of the complex electronic control. Malfunction indicator light in the combination meter indicates occurrence of a fault or trouble. • Further, against such a failure of sensors as may disable the drive, the fail-safe function is provided to ensure the minimal driveability. • The OBD system incorporated with the vehicles within this type of engine complies with OBD-II regulations. The OBD system monitors the components and the system malfunction listed in “Engine Section” which affects on emissions. • When the system decides that a malfunction occurs, malfunction indicator light illuminates. At the same time of the malfunction indicator light illumination or blinking, a DTC and a freeze frame engine conditions are stored into on-board computer.

EN(H4DOTC)(diag)-7

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General Description ENGINE (DIAGNOSTICS)

D: PREPARATION TOOL ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

1B022XU0

SUBARU SELECT MONITOR III KIT

Used for troubleshooting the electrical system.

499987500

CRANKSHAFT SOCKET

Used for rotating crankshaft.

ST1B022XU0

ST-499987500

EN(H4DOTC)(diag)-8

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Electrical Component Location ENGINE (DIAGNOSTICS)

4. Electrical Component Location A: LOCATION 1. CONTROL MODULE (1)

(3)

(4)

(2) EN-07794

(1) (2)

Engine control module (ECM) Malfunction indicator light

(3)

Delivery (test) mode fuse

(4)

Data link connector

(1) CHECK ENGINE

CHECK ENGINE

(2)

EN-07715

EN-07716

(3)

(4) EN-07511

EN(H4DOTC)(diag)-9

EN-07717

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Electrical Component Location ENGINE (DIAGNOSTICS)

2. SENSOR (8)

(5)

(1)

(9)

(2)

(4)

(6)

(3)

(5)

(7)

(9)

(6) EN-07795

(1) (2) (3)

Manifold absolute pressure sensor Engine coolant temperature sensor Electronic throttle control

(4)

Knock sensor

(7)

Crankshaft position sensor

(5)

Intake camshaft position sensor

(8)

(6)

Exhaust camshaft position sensor

(9)

Mass air flow and intake air temperature sensor Tumble generator valve ASSY

EN(H4DOTC)(diag)-10

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Electrical Component Location ENGINE (DIAGNOSTICS)

(1) (2)

EN-07751

EN-07747

(3) (4)

EN-07756

EN-07748

(5)

(6) EN-01798

EN-01929

(7)

(8)

EN-07862

(9)

EN-04992

EN(H4DOTC)(diag)-11

EN-07749

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Electrical Component Location ENGINE (DIAGNOSTICS)

(1)

(2)

(3)

(4) EN-07742

(1) (2)

Front oxygen (A/F) sensor Front catalytic converter

(3)

Rear oxygen sensor

(2) (1)

EN-07743

EN(H4DOTC)(diag)-12

(4)

Rear catalytic converter

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Electrical Component Location ENGINE (DIAGNOSTICS) (1) (2)

(3)

(4) EN-07796

(1) (2)

Fuel level sensor Fuel temperature sensor

(3)

Fuel tank pressure sensor

(4)

Fuel sub level sensor

(3)

(1)

(2) EN-07725

(4)

EN-07720

EN(H4DOTC)(diag)-13

EN-07719

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Electrical Component Location ENGINE (DIAGNOSTICS)

3. SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS (3)

(4)

(5)

(2)

(7)

(1)

(3)

(6)

(4)

(7)

(3)

(5) EN-07797

(1)

Wastegate control solenoid valve

(4)

Intake oil flow control solenoid valve

(6)

Tumble generator valve ASSY

(2)

Purge control solenoid valve 1

(5)

Exhaust oil flow control solenoid valve

(7)

Purge control solenoid valve 2

(3)

Ignition coil

EN(H4DOTC)(diag)-14

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Electrical Component Location ENGINE (DIAGNOSTICS)

(2)

(7)

(1) EN-07758

EN-07755

(3)

(4) EN-01936

EN-01937

(6)

(5)

EN-07762

EN(H4DOTC)(diag)-15

EN-07754

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Electrical Component Location ENGINE (DIAGNOSTICS)

(6) (5) (4) (3)

(2)

(11)

(7) (8) (9)

(1) (2) (3) (4) (5)

(1)

Starter Fuel pump Main relay A/F, oxygen sensor relay Electronic throttle control relay

(10)

(6) (7) (8) (9) (10)

(12) (13) (14)

Fuel pump relay Radiator main fan relay 1 Radiator main fan relay 2 Radiator sub fan relay Starter relay

EN(H4DOTC)(diag)-16

(11) (12) (13) (14)

EN-07798

Pressure control solenoid valve Canister Drain valve Drain filter

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Electrical Component Location ENGINE (DIAGNOSTICS)

(2) (1)

EN-07519

EN-07753

(3) (4) (8)

(5)

(7)

(6)

(9) EN-07726

EN-07521

(11)

(10) EN-07727

(14)

(13)

(12) EN-07723

EN(H4DOTC)(diag)-17

EN-07825

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Electrical Component Location ENGINE (DIAGNOSTICS)

4. TRANSMISSION • Solenoid valve and switch

(1)

EN-07524

(1)

Neutral position switch

EN(H4DOTC)(diag)-18

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION

TO A:

B134

7 6 5 4 3 17 16 15 14 13 12 11 27 26 25 24 23 22 21 34 33 32 31

TO B: 2 1 10 9 8 20 19 18 30 29 28

B135

TO C:

7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 35 34 33 32 31 30 29 28

B136

TO D:

6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 27 26 25 24 23 22 21 20 19 18 17 30 29 28 35 34 33 32 31

B137

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26

EN-05288

Crankshaft position sensor Front oxygen (A/F) sensor

Rear oxygen sensor

Terminal No.

Signal (+) Signal (–) Shield

B137 B137 B137

17 25 31

Signal (+) Signal (–) Shield Signal Shield Ground (sensor)

B136 B136 B136 B136 B136

19 18 9 20 9

2.8 — 3.2 2.4 — 2.7 0 0 0

2.8 — 3.2 2.4 — 2.7 0 0 — 0.9 0

— — — — —

B135

30

0

0



B136

6





Waveform

B136

5





Waveform

B135

6

0 — 13



Waveform

B137

22

1.0 — 1.4

1.0 — 1.4

After engine is warmed up.

B134

29

0

0

After engine is warmed up.

B136 B136 B136

22 10 11

— 0 0

0.3 — 4.5 0 0

— — —

B136

31

0.3 — 4.6

0.3 — 4.6



Front oxygen Signal 1 (A/F) sensor Signal 2 heater Rear oxygen sensor heater signal Engine coolant temperature sensor

Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 0 –7 — +7 0 0 0 0

Connector No.

Description

Signal Ground (sensor)

Signal Air flow sensor Shield Ground Intake air temperature sensor signal

Note Waveform — —

Wastegate control solenoid valve Starter switch Ignition switch

B134

33

0 or 10 — 13

0 or 12 — 14

Waveform

B136 B136

16 30

0 10 — 13

0 12 — 14

Cranking: 8 — 14 —

Neutral position switch

B136

35

ON: 0 OFF: 10 — 13

ON: 0 OFF: 12 — 14



EN(H4DOTC)(diag)-19

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 10 — 13 12 — 14

Connector No.

Terminal No.

B136

34

B137 B137

2 8

2.8 0

2.8 0

Back-up power supply

B136

2

10 — 13

12 — 14

Control module power supply

B137 B136

7 1

10 — 13 10 — 13

12 — 14 12 — 14

— —

#1

B134 B135 B134

19 22 21

5 5 0

5 5 0 or 5

— — Waveform

#2 #3 #4 #1 #2 #3 #4

B134 B134 B134 B134 B134 B134 B134

22 31 32 10 11 12 13

0 0 0 10 — 13 10 — 13 10 — 13 10 — 13

0 or 5 0 or 5 0 or 5 1 — 14 1 — 14 1 — 14 1 — 14

Waveform Waveform Waveform Waveform Waveform Waveform Waveform

Control Diagnosis signal

B136

33

0 or 5

0 or 5

Waveform

B135

10

0 or 10 — 13

12 — 14



Radiator fan relay 1 control

B135

11

ON: 0.5 or less OFF: 10 — 13

ON: 0.5 or less OFF: 12 — 14



Radiator fan relay 2 control

B135

12

ON: 0.5 or less OFF: 10 — 13

ON: 0.5 or less OFF: 12 — 14



Malfunction indicator light

B135

33





Engine speed output Purge control solenoid valve 1

B135

15



0 — 13 or more

B137

6

ON: 1 or less OFF: 10 — 13

ON: 1 or less OFF: 12 — 14

Waveform

B137

15

ON: 1 or less OFF: 10 — 13

ON: 1 or less OFF: 12 — 14

Waveform

B137

20

1.7 — 2.4

1.1 — 1.6

B134

19

5

5

Ground (sensor)

B134

29

0

0

SSM communication line

B135

14

1 or less ←→ 4 or more

1 or less ←→ 4 or more



Main

B134

18

0.64 — 0.72 (After engine is warmed up.)

Fully closed: Approx. 0.6 Fully open: Approx. 4.04

Sub

B134

28

0.64 — 0.72 Fully open: Approx. 4.04 1.51 — 1.58 Fully open: Approx. 4.232

1.51 — 1.58 (After engine is warmed up.)

Fully closed: Approx. 1.48 Fully open: Approx. 4.232

Power supply

B134

19

5

5



B134

29

0

0



B134

2

Duty waveform

Duty waveform

Drive frequency: 500 Hz

Description Delivery (test) mode fuse Knock sensor

Signal Shield

Sensor power supply

Ignition control

Fuel injector

Fuel pump control unit

Purge control solenoid valve 2 Manifold absolute pressure sensor

Electric throttle control

Signal Power supply

Ground (sensor) Electronic throttle control motor (+)

EN(H4DOTC)(diag)-20

Note When fuse is installed: 0 — — Ignition switch “OFF”: 10 — 13

Light “ON”: 1 or less Light “OFF”: 10 — 14 Waveform



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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Ignition SW ON Engine ON (engine OFF) (idling)

Connector No.

Terminal No.

B134

1

Duty waveform

Duty waveform

Drive frequency: 500 Hz

B135

7

10 — 13

12 — 14



B135

17

ON: 0 OFF: 10 — 13

ON: 0 OFF: 12 — 14

When ignition switch is turned to ON: ON

B134

17

ON: 10 — 13 OFF: 0

ON: 12 — 14 OFF: 0



B134

16

0

0



B134

34

ON: 10 — 13 OFF: 0

ON: 12 — 14 OFF: 0



B134

27

0

0



Signal (+)

B134

5

ON: 10 — 13 OFF: 0

ON: 12 — 14 OFF: 0



Signal (–)

B134

14

0

0



Signal (+)

B134

7

ON: 10 — 13 OFF: 0

ON: 12 — 14 OFF: 0



Signal (–)

B134

15

0

0



Intake camshaft position sensor (LH)

B137

16

0 or 5

0 or 5

Waveform

Intake camshaft position sensor (RH)

B137

24

0 or 5

0 or 5

Waveform

Exhaust camshaft position sensor (LH)

B137

29

0 or 5

0 or 5

Waveform

B137

23

0 or 5

0 or 5

Waveform

B137

30

0

0



B135

23

B136

4

Fully closed: 1 Fully opened: 3.3 0

Fully closed: 1 Fully opened: 3.3 0

B135

21

5

5



B135

29

0

0



B135

31

Fully closed: 1 Fully opened: 3.3

Fully closed: 1 Fully opened: 3.3



B135

22

5

5



B135

30

0

0



B135

26

ON: 0 OFF: 10 — 13

ON: 0 OFF: 12 — 14

ON: cranking

9

When clutch pedal is depressed: 0 When clutch pedal is released: 10 — 13

When clutch pedal is depressed: 0 When clutch pedal is released: 12 — 14



Description Electronic throttle control motor (–) Electronic throttle control motor power supply Electronic throttle control motor relay Intake oil flow Signal (+) control solenoid valve (LH) Signal (–) Intake oil flow Signal (+) control solenoid valve Signal (–) (RH) Exhaust oil flow control solenoid valve (LH) Exhaust oil flow control solenoid valve (RH)

Exhaust camshaft position sensor (RH) Camshaft position sensor ground Main sensor signal

Accelerator pedal position sensor

Shield Main power supply Ground (main sensor) Sub signal sensor Sub power supply Ground (sub sensor)

Starter relay

Clutch switch

B135

EN(H4DOTC)(diag)-21

Note

— —

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

Description

Brake switch 1 (brake switch)

Brake switch 2 (stop light switch)

Connector No.

Terminal No.

B136

15

B136

3

Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) When brake pedal is When brake pedal is depressed: 0 depressed: 0 When brake pedal is When brake pedal is released: 10 — 13 released: 12 — 14 When brake pedal is depressed: 10 — 13 When brake pedal is released: 0

When brake pedal is depressed: 12 — 14 When brake pedal is released: 0

When operating When operating nothing: 3.5 — 4.5 nothing: 3.5 — 4.5 When operating When operating RES/ACC: 2.5 — 3.5 RES/ACC: 2.5 — 3.5 When operating vehi- When operating vehicle distance setting: cle distance setting: 1.5 — 2.5 1.5 — 2.5 When operating SET/ When operating SET/ COAST: 0.5 — 1.5 COAST: 0.5 — 1.5 When operating can- When operating cancel: 0 — 0.5 cel: 0 — 0.5 ON: 0 ON: 0 OFF: 5 OFF: 5 — — — — 0 0

Note





Cruise control command switch

B136

12

Cruise control main switch

B136

13

(Hi) (Lo) Self-shutoff control Power steering oil pressure switch

B136 B136 B135

17 28 13

B137

28

B136

26

0

ON: 0 OFF: 12 — 14 0

11

Fully closed: 0.43 — 1.19 Fully open: 2.83 — 4.69

Fully closed: 0.43 — 1.19 Fully open: 2.83 — 4.69



B137

10

Fully closed: 0.43 — 1.19 Fully open: 2.83 — 4.69

Fully closed: 0.43 — 1.19 Fully open: 2.83 — 4.69



B134

26

0 or 10 — 13

0 or 12 — 14



B134

24

0 or 10 — 13

0 or 12 — 14



B134

25

0 or 10 — 13

0 or 12 — 14



B134

23

0 or 10 — 13

0 or 12 — 14



B135 B136

25 21

— 2.3 — 2.7

— 2.3 — 2.7

— —

B135

3

ON: 1 or less OFF: 10 — 13

ON: 1 or less OFF: 12 — 14



Drain valve

B135

4

ON: 1 or less OFF: 10 — 13

ON: 1 or less OFF: 12 — 14



Fuel temperature sensor

B136

23

2.5 — 3.8

2.5 — 3.8

Outside temperature: 25°C (77°F)

CAN communication

Oil level switch Tumble generator valve position sensor signal (RH)

Tumble generator valve position sensor signal (LH) Tumble generator valve (RH closed) Tumble generator valve (LH closed) Tumble generator valve (RH open) Tumble generator valve (LH open) Immobilizer communication Fuel tank pressure sensor Pressure control solenoid valve

B137

10 — 13

EN(H4DOTC)(diag)-22



— — — — — Oil level LOW: 10 — 14

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

Description

Sensor

Ground

Engine 1 Engine 2 Engine 3 Engine 4 Engine 5 Body

Connector No.

Terminal No.

B134 B135 B134 B134 B134 B137 B137 B136

29 30 6 4 3 1 3 4

Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

EN(H4DOTC)(diag)-23

Note — — — — — — — —

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

Input/output name: • Crankshaft position sensor • Intake camshaft position sensor RH • Intake camshaft position sensor LH • Exhaust camshaft position sensor RH • Exhaust camshaft position sensor LH Measuring condition: • After warming-up • At idling

CRANKSHAFT POSITION SENSOR

0

ONE CRANKSHAFT ROTATION

INTAKE CAMSHAFT POSITION SENSOR RH

0

ONE CAMSHAFT ROTATION

INTAKE CAMSHAFT POSITION SENSOR LH

0

EXHAUST CAMSHAFT POSITION SENSOR RH

0

EXHAUST CAMSHAFT POSITION SENSOR LH

0 10 ms 5V

EN(H4DOTC)(diag)-24

EN-07431

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

F/B FUSE No. 4 DATA LINK CONNECTOR

B9 C2

M/B FUSE No. 12

CLUTCH SWITCH

STARTER MOTOR

B14

C16

C34

IGNITION SWITCH

DELIVERY (TEST) MODE FUSE

B26

F/B FUSE No. 21 STARTER RELAY

CLUTCH STROKE SENSOR (CLUTCH START SWITCH) C4

1

JOINT CONNECTOR

1

C35

ACCELERATOR PEDAL POSITION SENSOR

B23

NEUTRAL POSITION SWITCH

B21 B31

C30

F/B FUSE No. 12

FUEL PUMP RELAY

B29 FUEL PUMP CONTROL UNIT

M/B FUSE No. 20

C33 B10

JOINT CONNECTOR

FUEL TEMPERATURE SENSOR

8

B22

B30

FUEL PUMP

2

C23

2 3 4 5

6

7

EN-07799

EN(H4DOTC)(diag)-25

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

M/B FUSE No. 13

8

ELECTRONIC THROTTLE CONTROL RELAY

M/B FUSE No. 16

M/B FUSE No. 15

F/B FUSE No. 7 F/B FUSE No. 5

A21 B7

IGNITION COIL No. 1

B17 A/F, OXYGEN SENSOR RELAY

MAIN RELAY

A22 IGNITION COIL No. 2

A31 IGNITION COIL No. 3

B13 A32

IGNITION COIL No. 4 C1

12

D7 PURGE CONTROL SOLENOID VALVE 1

D6

PURGE CONTROL SOLENOID VALVE 2

D15

INTAKE CAMSHAFT POSITION SENSOR LH

D16

B15

BODY INTEGRATED UNIT (CAN COMMUNICATION)

B33

COMBINATION METER

D24 INTAKE CAMSHAFT POSITION SENSOR RH

EXHAUST CAMSHAFT POSITION SENSOR LH

D30

POWER STEERING OIL PRESSURE SWITCH

D29 D28

D23 EXHAUST CAMSHAFT POSITION SENSOR RH C26

9 10

OIL LEVEL SWITCH

EN-07800

EN(H4DOTC)(diag)-26

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

6

10

A10

FUEL INJECTOR No. 1

A18

A28 A12

FUEL INJECTOR No. 3

12 A1

A2 A13

FUEL INJECTOR No. 4

A19

MANIFOLD ABSOLUTE PRESSURE SENSOR

A33

WASTEGATE CONTROL SOLENOID VALVE

D20 A29

ENGINE COOLANT TEMPERATURE SENSOR

3

C31 C11

ELECTRONIC THROTTLE CONTROL

A11

FUEL INJECTOR No. 2

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

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D22

C22

C10

11

12

EN-07801

EN(H4DOTC)(diag)-27

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

12

9

FRONT OXYGEN (A/F) SENSOR

C18

A23

C19

A24

11

TUMBLE GENERATOR VALVE ASSY LH

C5 C6 C9

5

C20 REAR OXYGEN SENSOR

D10

A25

TUMBLE GENERATOR VALVE ASSY RH

A26

12

D11 B6

A17

INTAKE OIL FLOW CONTROL SOLENOID VALVE LH

A16

A34 A5 EXHAUST OIL FLOW CONTROL SOLENOID VALVE LH

INTAKE OIL FLOW CONTROL SOLENOID VALVE RH

A27

A14

D17 A7 EXHAUST OIL FLOW CONTROL SOLENOID VALVE RH

CRANKSHAFT POSITION SENSOR

D25 D31

A15

12 KNOCK SENSOR

D2 D8

12

EN-07802

EN(H4DOTC)(diag)-28

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

10 4 7

STOP LIGHT SWITCH

C3

C21 B3

BRAKE SWITCH

C15

FUEL TANK PRESSURE SENSOR

PRESSURE CONTROL SOLENOID VALVE

B4 DRAIN VALVE

BODY INTEGRATED UNIT (IMMOBILIZER)

B25 C13

CRUISE CONTROL SWITCH C17 BODY INTEGRATED UNIT (CAN COMMUNICATION)

C12

C28

10

SUB FAN RELAY

B11

A3 D1 A4 D3

MAIN FAN RELAY

B12 A6

ENGINE GROUND

EN-07803

EN(H4DOTC)(diag)-29

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Engine Condition Data ENGINE (DIAGNOSTICS)

6. Engine Condition Data A: ELECTRICAL SPECIFICATION Remarks

Specification 17.6 — 35.64 (%): Idling 13.2 — 26.73 (%): 2,500 rpm racing

Engine load

Measuring condition: • After engine is warmed up. • Place the shift lever in neutral position. • Turn the A/C to OFF. • Turn all the accessory switches to OFF.

EN(H4DOTC)(diag)-30

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Data Link Connector ENGINE (DIAGNOSTICS)

7. Data Link Connector A: NOTE This connector is used for Subaru Select Monitor. CAUTION: Do not connect any scan tools other than Subaru Select Monitor or general scan tool because the circuit for Subaru Select Monitor may be damaged.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

EN-07824

Terminal No. 1 2 3 4 5 6 7 8

Contents Empty Empty Empty Ground Ground CAN communication (Hi) Subaru Select Monitor signal Empty

Terminal No. 9 10 11 12 13 14 15 16

Contents Empty Empty Empty Empty Empty CAN communication (Lo) Empty Power supply

EN(H4DOTC)(diag)-31

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General Scan Tool ENGINE (DIAGNOSTICS)

8. General Scan Tool A: OPERATION 1. HOW TO USE GENERAL SCAN TOOL 1) Prepare a scan tool (general scan tool) required by SAE J1978. 2) Connect the general scan tool to the data link connector located in the lower portion of the instrument panel (on the driver’s side).

EN-07712

3) Using the general scan tool, call up each data. General scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic data (2) MODE $02: Powertrain freeze frame data (3) MODE $03: Emission-related powertrain DTC (4) MODE $04: Clear/Reset emission-related diagnostic information (5) MODE $06: Request on-board monitoring test results for intermittently monitored systems (6) MODE $07: Request on-board monitoring test results for continuously monitored systems (7) MODE $09: Request vehicle information 4) Read out the data according to repair procedures. (For detailed operation procedure, refer to the general scan tool operation manual.) NOTE: For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”.

EN(H4DOTC)(diag)-32

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General Scan Tool ENGINE (DIAGNOSTICS)

2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA) Refer to data denoting the current operating condition of analog input/output, digital input/output or the powertrain system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. PID $01 $03 $04 $05 $06 $07 $0B $0C $0D $0E $0F $10 $11 $13 $15 $1C $1F $21 $24 $2E $2F $30 $31 $32 $33 $34 $3C $41 $42 $43 $44 $45 $46 $47 $49 $4A $4C $4D $4E $51 $5A $65

Data Number of emission-related powertrain DTC, and malfunction indicator light status and diagnosis support information Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim Long term fuel trim Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance Intake air temperature Intake air amount Throttle valve opening angle Air fuel ratio sensor Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor Supporting OBD system Elapsed time after starting the engine Running distance after MIL turns on A/F value and A/F sensor output voltage Evaporative purge Fuel level Number of warm ups after DTC clear Travel distance after DTC clear Fuel tank pressure Atmospheric pressure A/F sensor λ value, current Catalytic temperature Diagnostic monitor of each drive cycle ECM power voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute acceleration opening angle 1 Absolute acceleration opening angle 2 Target throttle opening angle Engine operation time during MIL on Elapsed time after DTC clear Fuel used Relative acceleration opening angle Neutral status

Unit of measure — — % °C % % kPa rpm MPH ° °C g/s % — V and % — sec miles – and V % % — miles Pa kPa – and mA °C — V % — % °C % % % % min min — % —

NOTE: Refer to general scan tool manufacturer’s instruction manual to access the generic OBD-II PID (MODE $01).

EN(H4DOTC)(diag)-33

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General Scan Tool ENGINE (DIAGNOSTICS)

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) Refer to data denoting the operating condition when trouble is sensed by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. PID $02 $03 $04 $05 $06 $07 $0B $0C $0D $0E $0F $10 $11 $13 $15 $1C $1F $2E $2F $32 $33 $42 $43 $44 $45

Data DTC that caused the freeze frame data storage required by CARB Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim Long term fuel trim Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance Intake air temperature Intake air amount Throttle valve opening angle Air fuel ratio sensor Rear oxygen sensor voltage, compensation value Supporting OBD system Elapsed time after starting the engine Evaporative purge Fuel level Fuel tank pressure Atmospheric pressure ECM power voltage Absolute load A/F target lambda Relative throttle opening angle

$46 $47 $49 $4A $4C $65

Ambient temperature Absolute throttle opening angle 2 Absolute acceleration opening angle 1 Absolute acceleration opening angle 2 Target throttle opening angle Neutral status

Unit of measure — — % °C % % kPa rpm MPH ° °C g/s % — V and % — sec % % Pa kPa V % — % °C % % % % —

NOTE: Refer to general scan tool manufacturer’s operation manual to access freeze frame data (MODE $02).

4. MODE $03 (EMISSION-RELATED POWERTRAIN DTC) Refer to “List of Diagnostic Trouble Code (DTC)” for information about data denoting emission-related powertrain DTC.

5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION) Refer to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic information). NOTE: • Refer to general scan tool manufacturer’s instruction manual to clear the emission-related diagnostic information (MODE $04). • Initial diagnosis of electronic throttle control is performed after memory clearance. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine.

EN(H4DOTC)(diag)-34

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General Scan Tool ENGINE (DIAGNOSTICS)

6. MODE $06 Refer to test value of troubleshooting and data of test limit indicated on the support data bit sequence table. A list of the support data is shown in the following table. OBDMID

TID $81 $82 $83 $84 $85 $86 $87 $88 $07 $08 $A5 $05 $06 $89 $8B

SID $0A $8D $14 $1E $1E $20 $0B $0B $0B $0B $0B $10 $10 $20 $9D

$8C $8D $8E $8B

$9D $9D $9D $9D

$8C $8D $8E $93 $94 $95 $A6

$9D $9D $9D $FE $FE $FE $FE

$96 $97 $98 $99 $9A $9B

$FE $FE $FE $24 $24 $14

$42

$9C $9D

$24 $24

Oxygen sensor heater failure (Bank 1 Sensor 2)

$A1

$0B $0C

$24 $24

Misfire monitoring (All cylinders)

$A2

$0B $0C

$24 $24

Misfire monitoring (#1 cylinder)

$A3

$0B $0C

$24 $24

Misfire monitoring (#2 cylinder)

$A4

$0B $0C

$24 $24

Misfire monitoring (#3 cylinder)

$A5

$0B $0C

$24 $24

Misfire monitoring (#4 cylinder)

$01

$02

$21

$35

$36

$39 $3B

$3C $3D $41

Diagnostic item A/F sensor continuity failure (Bank 1 Sensor 1)

A/F sensor range failure (Bank 1 Sensor 1) A/F sensor response failure (Bank 1 Sensor 1) Oxygen sensor circuit failure (Bank 1 Sensor 2)

Oxygen sensor drop failure (Bank 1 Sensor 2)

Oxygen sensor response failure (Bank 1 Sensor 2) Catalyst deterioration diagnosis (Bank 1)

VVT monitor bank 1

VVT monitor bank 2

Evaporative emission control system leak detected (Fuel filler cap off) Evaporative emission control system (0.04 inch leak)

Evaporative emission control system (0.02 inch leak) Evaporative emission control system (Purge flow) A/F sensor heater failure (Bank 1 Sensor 1) A/F sensor heater characteristics failure (Bank 1 Sensor 1)

EN(H4DOTC)(diag)-35

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General Scan Tool ENGINE (DIAGNOSTICS)

7. MODE $07 Refer to the data of DTC (pending code) for troubleshooting result about emission in the first time.

8. MODE $09 Refer to the data of vehicle specification (V.I.N., calibration ID, etc.).

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Subaru Select Monitor ENGINE (DIAGNOSTICS)

9. Subaru Select Monitor A: OPERATION 1. HOW TO USE THE SUBARU SELECT MONITOR NOTE: For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

2. READ CURRENT DATA FOR ENGINE (NORMAL MODE) NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • A list of the support data is shown in the following table. Contents Engine load Engine coolant temperature signal A/F correction #1 A/F learning #1

Display Engine Load Coolant Temp. A/F Correction #1 A/F Learning #1

Intake manifold absolute pressure

Mani. Absolute Pressure

Engine speed signal

Engine Speed

Meter vehicle speed signal Ignition timing signal Intake air temperature signal

Vehicle Speed Ignition Timing Intake Air Temp.

Intake air amount

Mass Air Flow

Throttle opening angle signal Rear oxygen sensor voltage Battery voltage Mass air flow voltage Injection 1 pulse width

Throttle Opening Angle Rear O2 Sensor Battery Voltage Air Flow Sensor Voltage Fuel Injection #1 Pulse

Atmospheric pressure

Atmosphere Pressure

Intake manifold relative pressure

Mani. Relative Pressure

Learned ignition timing Acceleration opening angle signal Fuel temperature signal Primary supercharged pressure control signal Purge control solenoid duty ratio Tumble generator valve RH opening signal Tumble generator valve LH opening signal Fuel pump duty ratio AVCS advance angle amount RH AVCS advance angle amount LH Oil flow control solenoid valve duty ratio RH Oil flow control solenoid valve duty ratio LH Oil flow control solenoid valve current RH Oil flow control solenoid valve current LH A/F sensor current value 1 A/F sensor resistance value 1 A/F sensor output lambda 1

Learned Ignition Timing Accel. Opening Angle Fuel Temp. Primary Control CPC Valve Duty Ratio TGV Position Sensor R TGV Position Sensor L Fuel Pump Duty VVT Adv. Ang. Amount R VVT Adv. Ang. Amount L OCV Duty R OCV Duty L OCV Current R OCV Current L A/F Sensor #1 Current A/F Sensor #1 Resistance A/F Sensor #1

Unit of measure % °C or °F % %

Note (at idling) 21.0% 80 — 100°C or 176 — 212°F –10 — +10% –15 — +15%

mmHg, kPa, inHg or psig

220 — 275 mmHg, 29.5 — 37 kPa, 8.7 — 10 inHg or 4.2 — 5.3 psig

rpm km/h or MPH deg °C or °F

EN(H4DOTC)(diag)-37

g/s or lb/m % V V V ms

630 — 770 rpm (Agree with the tachometer indication) 0 km/h or 0 MPH (at parking) 10 — 15 deg 20 — 50°C or 68 — 122°F 2.1 — 3.1 g/s or 0.35 — 0.40 lb/m 2.0 — 2.4% 0 — 1.0 V 12 — 15 V 1.0 — 1.7 V 1.2 — 2.2 ms

mmHg, kPa, inHg or psig



mmHg, kPa, inHg or psig deg % °C or °F % % V V % deg deg % % mA mA mA Ω —

Air intake absolute pressure — Atmospheric pressure 0 deg 0.0% +28°C or 82°F 0.0% 0 — 25% 0.81 V 0.81 V 30 — 40% ±5 deg ±5 deg 0 — 20% 0 — 20% 40 — 100 mA 40 — 100 mA –20 — 20 mA 27 — 35 mA 1.0

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents A/F correction #3 A/F learning #3 Throttle motor duty Throttle motor voltage Sub throttle sensor voltage Main throttle sensor voltage Sub accelerator sensor voltage Main acceleration sensor voltage Memory vehicle speed Fuel level sensor resistance Odometer Exhaust AVCS retard angle amount RH Exhaust AVCS retard angle amount LH Exhaust oil flow control solenoid valve duty ratio RH Exhaust oil flow control solenoid valve duty ratio LH Exhaust oil flow control solenoid valve current value RH Exhaust oil flow control solenoid valve current value LH #1 cylinder roughness monitor #2 cylinder roughness monitor #3 cylinder roughness monitor #4 cylinder roughness monitor Knock sensor correction

Display A/F Correction #3 A/F Learning #3 Throttle Motor Duty Throttle Motor Voltage Sub-Throttle Sensor Main-Throttle Sensor Sub-Accelerator Sensor Main-Accelerator Sensor Memorized Cruise Speed Fuel level resistance Odometer Exh. VVT Retard Ang. R Exh. VVT Retard Ang. L

Unit of measure % % % V V V V V km/h or MPH Ω km deg deg

Note (at idling) 0.00% 0.00% –5% 12 — 15 V 1.5 V 0.6 V 1.1 V 1.0 V — 4 — 96 Ω — ±5 deg ±5 deg

Exh. OCV Duty R

%

0 — 20%

Exh. OCV Duty L

%

0 — 20%

Exh. OCV Current R

mA

40 — 100 mA

Exh. OCV Current L

mA

40 — 100 mA

Roughness Monitor #1 Roughness Monitor #2 Roughness Monitor #3 Roughness Monitor #4 Knocking Correction

— — — — deg

0 0 0 0 0.0 deg

mmHg, kPa, inHg or psig —

+8.8 mmHg, +1.2 kPa, +0.4 inHg or 0.2 psig OFF

— —

OFF OFF



OFF

— — — — — — —

ON ON ON OFF (when OFF) OFF (when OFF) OFF Rich/Lean

— — — — — — — — — — —

OFF ON ON OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF Closing direction

Fuel tank pressure signal

Fuel Tank Pressure

AT vehicle ID signal

AT Vehicle ID Signal

Delivery (test) mode terminal D-check require Flag

Test Mode Signal D-check Require Flag

Neutral position switch signal Soft idle switch signal Ignition switch signal Power steering switch signal Air conditioning switch signal Starter switch signal Rear oxygen monitor

Delivery Mode Connector (Test Mode Connector) Neutral Position Switch Idle Switch Signal Ignition Switch P/S Switch Signal A/C Switch Starter Switch Rear O2 Rich Signal

Knocking signal Crankshaft position sensor signal Camshaft position sensor signal Rear defogger switch signal Blower fan switch signal Light switch signal Radiator fan relay 1 signal Radiator fan relay 2 signal Pressure control solenoid valve signal Tumble generator valve output signal Tumble generator valve driving signal

Knocking Signal Crankshaft Position Sig. Camshaft Position Sig. Rear Defogger SW Blower Fan SW Light Switch Radiator Fan Relay #1 Radiator Fan Relay #2 PCV Solenoid Valve TGV Output TGV Drive

Delivery (test) mode terminal

EN(H4DOTC)(diag)-38

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents Drain valve signal Purge control solenoid valve 2 signal Vehicle dynamics control (VDC) torque down prohibition output

Display Vent. Solenoid Valve CPC Solenoid 2

Unit of measure — —

Note (at idling) OFF (when OFF) OFF (when OFF)

Ban of Torque Down



ON

Vehicle dynamics control (VDC) torque down demand

Request Torque Down VDC



OFF

ETC motor relay signal Clutch switch signal Stop light switch signal SET/COAST switch signal RES/ACC switch signal Brake switch signal Main switch signal Body integrated unit data reception Body integrated unit counter update Cruise control cancel switch signal Malfunction indicator light signal Oil level switch signal

ETC Motor Relay Clutch Switch Stop Light Switch SET/COAST Switch RESUME/ACCEL Switch Brake Switch Main Switch Body Int. Unit Data Body Int. Unit Count CC Cancel SW MIL On Flag Oil level switch

— — — — — — — — — — — —

ON OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) OFF (when OFF) ON ON OFF (when OFF) OFF (when unlit) HIGH level

3. READ CURRENT DATA FOR ENGINE (OBD MODE) NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • A list of the support data is shown in the following table. Contents Number of diagnosis code

Display Number of Diag. Code:

Condition of malfunction indicator light Monitoring test of misfire Monitoring test of misfire

MI(MIL) Misfire monitoring (Supp) Misfire monitoring (Rdy) Fuel system monitoring (Supp)

Monitoring test of fuel system

Referential value (at idling) 0

Unit of measure —

OFF YES YES

— — —

YES



Monitoring test of fuel system

Fuel system monitoring (Rdy)

YES



Monitoring test of comprehensive component

Component monitoring (Supp)

YES



Monitoring test of comprehensive component

Component monitoring (Rdy)

YES



Test of catalyst Test of catalyst Test of heating-type catalyst Test of heating-type catalyst

Catalyst Diagnosis (Supp) Catalyst Diagnosis (Rdy) Heated catalyst (Supp) Heated catalyst (Rdy)

YES NO NO N/A

— — — —

Test of evaporative emission purge control system

Evaporative purge system (Supp)

YES



Test of evaporative emission purge control system

Evaporative purge system (Rdy)

NO



NO



N/A



NO



N/A YES NO

— — —

Secondary air system test Secondary air system test Test of air conditioning system refrigerant Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor

Secondary air system (Supp) Secondary air system (Rdy) A/C system refrigerant (Supp) A/C system refrigerant (Rdy) Oxygen sensor (Supp) Oxygen sensor (Rdy)

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents Test of oxygen sensor heater Test of oxygen sensor heater Test of EGR system Test of EGR system Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim by front oxygen (A/F) sensor (Bank 1)

Display O2 Heater Diagnosis (Supp) O2 Heater Diagnosis (Rdy) EGR system (Supp) EGR system (Rdy) Fuel system for Bank 1 Calculated load value Coolant Temp.

Referential value (at idling) YES YES NO N/A Cl_normal 19.2 96

Unit of measure — — — — — % °C

Short term fuel trim B1

17.2

%

Long term fuel trim B1

5.5

%

Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal #1 Cylinder ignition timing Intake air temperature signal Intake air amount Throttle position signal Oxygen sensor (Bank 1 Sensor 2) A/F correction (Bank 1 Sensor 2) On-board diagnostic system Front oxygen (A/F) sensor (Bank 1 Sensor 1) Oxygen sensor (Bank 1 Sensor 2) Elapsed time after engine start Travel distance after the malfunction indicator light illuminates

Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Oxygen sensor #12 Short term fuel trim #12 OBD System Oxygen sensor #11 Oxygen sensor #12 Time Since Engine Start

32 846 0 13.5 44 3.6 13 0.1 — 0.7 0.0 OBD/OBD2 Supported Supported —

kPa rpm km/h ° °C g/s % V % — — — sec

Lighted MI lamp history



km

A/F lambda signal (Bank 1 Sensor 1) A/F sensor output signal (Bank 1 Sensor 1) Evaporative purge Fuel level signal Number of warm ups after DTC clear Travel distance after DTC clear Fuel tank pressure signal Atmospheric pressure signal A/F lambda signal (Bank 1 Sensor 1) A/F sensor output signal (Bank 1 Sensor 1) Catalyst temperature #1 Monitoring test of misfire Monitoring test of misfire

A/F Sensor #11 A/F Sensor #11 Commanded Evap Purge Fuel Level Number of warm-ups Meter since DTC cleared Fuel Tank Pressure Atmosphere Pressure A/F Sensor #11 A/F Sensor #11 Catalyst Temperature #11 Misfire monitoring (Enable) Misfire monitoring (Comp) Fuel system monitoring (Enable)

0.951 2.468 0 — — — 1171.5 Atmospheric pressure 0.957 –0.18 — YES YES

— V % % — km Pa kPa — mA °C — —

YES



Monitoring test of fuel system Monitoring test of fuel system

Fuel system monitoring (Comp)

YES



Monitoring test of comprehensive component

Component monitoring (Enable)

NO



Monitoring test of comprehensive component

Component monitoring (Comp)

NO



Test of catalyst Test of catalyst Test of heating-type catalyst Test of heating-type catalyst

Catalyst Diagnosis (Enable) Catalyst Diagnosis (Comp) Heated catalyst (Enable) Heated catalyst (Comp)

YES NO N/A N/A

— — — —

EN(H4DOTC)(diag)-40

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents

Display Evaporative purge system Test of evaporative emission purge control system (Enable)

Referential value (at idling)

Unit of measure

NO



Evaporative purge system (Comp) Secondary air system (Enable) Secondary air system (Comp)

NO



N/A



N/A



Test of air conditioning system refrigerant

A/C system refrigerant (Enable)

N/A



Test of air conditioning system refrigerant

A/C system refrigerant (Comp)

N/A



Test of oxygen sensor Test of oxygen sensor

Oxygen sensor (Enable) Oxygen sensor (Comp)

YES NO

— —

Test of oxygen sensor heater

O2 Heater Diagnosis (Enable)

YES



Test of oxygen sensor heater

O2 Heater Diagnosis (Comp)

YES



N/A N/A 13.848 21 0.993 2 Ambient temperature 31 13 13 0

— — V % — % °C % % % %



min

— GAS 0 NEUT

min — % —

Test of evaporative emission purge control system Secondary air system test Secondary air system test

Test of EGR system Test of EGR system ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Engine operating time while malfunction indicator light lit Elapsed time after DTC clear Type of fuel Relative acceleration opening angle Neutral condition

EGR system (Enable) EGR system (Comp) Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont. Time while MIL lighted Time since DTC cleared Type of fuel Relative Accelera. Pos. MT gear status

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Subaru Select Monitor ENGINE (DIAGNOSTICS)

4. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE) NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • A list of the support data is shown in the following table. Contents DTC of freeze frame data Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim by front oxygen (A/F) sensor (Bank 1) Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal Ignition timing adv. #1 Intake air temperature Amount of intake air Throttle valve angle Oxygen sensor #12 A/F correction #12 OBD system Oxygen sensor #11 Oxygen sensor #12 Elapsed time after starting engine Evaporative purge Fuel level Fuel tank pressure Atmospheric pressure ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Neutral condition

Display Freeze frame data Fuel system for Bank 1 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Oxygen sensor #12 Short term fuel trim #12 OBD System Oxygen sensor #11 Oxygen sensor #12 Time Since Engine Start Commanded Evap Purge Fuel Level Fuel Tank Pressure Atmosphere Pressure Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont. MT gear status

5. V.I.N. REGISTRATION 1) On «Main Menu» display, select {Each System Check}. 2) On «System Selection Menu» display, select {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On «Engine Diagnosis» display, select {Entry VIN}. 5) Perform the procedures shown on the display screen.

EN(H4DOTC)(diag)-42

Unit of measure DTC — % °C or °F % % mmHg, kPa, inHg or psi rpm km/h or MPH ° °C g/s % V % — Supported Supported sec % % mmHg, Pa, inHg or psig mmHg, kPa, inHg or psig V % — % °C or °F % % % % —

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Read Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10.Read Diagnostic Trouble Code (DTC) A: OPERATION 1. SUBARU SELECT MONITOR NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”.

2. GENERAL SCAN TOOL Refer to data denoting emission-related powertrain DTC. For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”. NOTE: Refer to general scan tool manufacturer’s instruction manual to access powertrain DTC (MODE $03).

EN(H4DOTC)(diag)-43

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Inspection Mode ENGINE (DIAGNOSTICS)

11.Inspection Mode A: PROCEDURE Perform the diagnosis shown in the following DTC table. When performing the diagnosis not listed in “List of Diagnostic Trouble Code (DTC)”, refer to the item on the drive cycle. DTC P0011 P0014 P0016 P0017 P0018 P0019 P0021 P0024 P0031 P0032 P0037 P0038 P0102 P0103 P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0131 P0132 P0137 P0138 P0140 P0182 P0183 P0222 P0223 P0230 P0245 P0327 P0328 P0335 P0336 P0340 P0345 P0365 P0390 P0447

Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Exhaust AVCS System 1 (Range/Performance) Crankshaft Position - Camshaft Position Correlation (Bank1) Crank and Cam Timing B System Failure (Bank 1) Crankshaft Position - Camshaft Position Correlation (Bank2) Crank and Cam Timing B System Failure (Bank 2) Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 2) Exhaust AVCS System 2 (Range/Performance) HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/Switch “A” Circuit Low Throttle/Pedal Position Sensor/Switch “A” Circuit High O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) Fuel Temperature Sensor “A” Circuit Low Input Fuel Temperature Sensor “A” Circuit High Input Throttle/Pedal Position Sensor/Switch “B” Circuit Low Throttle/Pedal Position Sensor/Switch “B” Circuit High Fuel Pump Primary Circuit Turbo/Super Charger Wastegate Solenoid “A” Low Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor) Knock Sensor 1 Circuit High (Bank 1 or Single Sensor) Crankshaft Position Sensor “A” Circuit Crankshaft Position Sensor “A” Circuit Range/Performance Camshaft Position Sensor “A” Circuit (Bank 1 or Single Sensor) Camshaft Position Sensor “A” Circuit (Bank 2) Camshaft Position Sensor “B” Circuit (Bank 1) Camshaft Position Sensor “B” Circuit (Bank 2) Evaporative Emission Control System Vent Control Circuit Open

EN(H4DOTC)(diag)-44

Condition — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

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Inspection Mode ENGINE (DIAGNOSTICS) DTC P0448 P0452 P0453 P0458 P0462 P0463 P0500 P0512 P0513 P0604 P0605 P0607 P0638 P0851 P0852 P1152 P1153 P1160 P1400 P1420 P1518 P1560 P1570 P1571 P1572 P1574 P1576 P1577 P1578 P2006 P2007 P2008 P2009 P2011 P2012 P2016 P2017 P2021 P2022 P2088 P2089 P2090 P2091 P2092 P2093 P2094 P2095 P2101 P2102 P2103

Item Evaporative Emission Control System Vent Control Circuit Shorted Evaporative Emission Control System Pressure Sensor Low Input Evaporative Emission Control System Pressure Sensor High Input Evaporative Emission System Purge Control Valve Circuit Low Fuel Level Sensor “A” Circuit Low Fuel Level Sensor “A” Circuit High Vehicle Speed Sensor “A” Starter Request Circuit Incorrect Immobilizer Key Internal Control Module Random Access Memory (RAM) Error Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/Performance (Bank 1) Park/Neutral Switch Input Circuit Low Park/Neutral Switch Input Circuit High O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) Return Spring Failure Fuel Tank Pressure Control Solenoid Valve Circuit Low Fuel Tank Pressure Control Sol. Valve Circuit High Starter Switch Circuit Low Input Back-Up Voltage Circuit Malfunction Antenna Reference Code Incompatibility IMM Circuit Failure Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Intake Manifold Runner Control Stuck Closed (Bank 1) Intake Manifold Runner Control Stuck Closed (Bank 2) Intake Manifold Runner Control Circuit / Open (Bank 1) Intake Manifold Runner Control Circuit Low (Bank 1) Intake Manifold Runner Control Circuit / Open (Bank 2) Intake Manifold Runner Control Circuit Low (Bank 2) Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 1) Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 1) Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 2) Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 2) Intake Camshaft Position Actuator Control Circuit Low (Bank 1) Intake Camshaft Position Actuator Control Circuit High (Bank 1) Exhaust Camshaft Position Actuator Control Circuit Low (Bank 1) Exhaust Camshaft Position Actuator Control Circuit High (Bank 1) Intake Camshaft Position Actuator Control Circuit Low (Bank 2) Intake Camshaft Position Actuator Control Circuit High (Bank 2) Exhaust Camshaft Position Actuator Control Circuit Low (Bank 2) Exhaust Camshaft Position Actuator Control Circuit High (Bank 2) Throttle Actuator Control Motor Circuit Range/Performance Throttle Actuator Control Motor Circuit Low Throttle Actuator Control Motor Circuit High

EN(H4DOTC)(diag)-45

Condition — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

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Inspection Mode ENGINE (DIAGNOSTICS) DTC P2109 P2122 P2123 P2127 P2128 P2135 P2138 P2227 P2228 P2229 P2419 P2420 U0073 U0101 U0122 U0140 U0402 U0416 U0422

Item Throttle/Pedal Position Sensor “A” Minimum Stop Performance Throttle/Pedal Position Sensor/Switch “D” Circuit Low Input Throttle/Pedal Position Sensor/Switch “D” Circuit High Input Throttle/Pedal Position Sensor/Switch “E” Circuit Low Input Throttle/Pedal Position Sensor/Switch “E” Circuit High Input Throttle/Pedal Position Sensor/Switch “A”/“B” Voltage Correlation Throttle/Pedal Position Sensor/Switch “D”/“E” Voltage Correlation Atmospheric Pressure Sensor Range/Performance Barometric Pressure Circuit Low Barometric Pressure Circuit High Evaporative Emission System Switching Valve Control Circuit Low Evaporative Emission System Switching Valve Control Circuit High CAN Failure, Bus ‘OFF’ Detection CAN (TCU) Data not Loaded CAN (VDC) Data not Loaded CAN (BCU) Data not Loaded CAN (TCU) Data Abnormal CAN (VDC) Data Abnormal CAN (BCU) Data Abnormal

1. PREPARATION FOR THE INSPECTION MODE 1) Check that the battery voltage is 12 V or more and fuel remains approx. half [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8 Imp gal)]. 2) Lift up the vehicle using a garage jack and place it on rigid racks, or drive the vehicle onto free rollers. WARNING: • Before lifting up the vehicle, ensure parking brakes are applied. • Do not use a pantograph jack in place of a rigid rack. • Secure a rope or wire to the front or rear towing hooks to prevent the lateral runout of front wheels. • Before rotating the wheels, make sure that there is no one in front of the vehicle. Besides while the wheels are rotating, make sure that no one approaches the vehicle front side. • Make sure that there is nothing around the wheels. For AWD model, pay special attention to all four wheels. • While servicing, do not depress or release the clutch pedal or accelerator pedal quickly regardless of the engine speed. Quick operation may cause the vehicle to drop off the free roller.

Condition — — — — — — — — — — — — — — — — — — —

• To prevent the vehicle from slipping due to vibration, do not place anything between rigid rack and the vehicle.

(A)

(B)

(A) Rigid rack (B) Free roller

EN(H4DOTC)(diag)-46

EN-00041

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Inspection Mode ENGINE (DIAGNOSTICS)

2. SUBARU SELECT MONITOR 1) Check that no DTC remains after clearing memory. 2) Warm up the engine. 3) Prepare the Subaru Select Monitor kit.

CAUTION: Do not connect any scan tools except Subaru Select Monitor or general scan tool.

EN-07712

EN-05692

4) Prepare PC with Subaru Select Monitor installed. 5) Connect the USB cable to SDI (Subaru Diagnosis Interface) and USB port on the personal computer (dedicated port for the Subaru Select Monitor). NOTE: The dedicated port for the Subaru Select Monitor means the USB port which was used to install the Subaru Select Monitor. 6) Connect the diagnosis cable to SDI. 7) Install the delivery (test) mode fuse (A) of the main fuse box.

(A)

EN-07555

8) Connect SDI to data link connector located in the lower portion of the instrument panel (on the driver’s side).

9) Start the PC. 10) Turn the ignition switch to ON (engine OFF) and run the “PC application for Subaru Select Monitor”. 11) On «Main Menu» display, select {Each System Check}. 12) On «System Selection Menu» display, select {Engine Control System}. 13) Click the [OK] button after the information of engine type has been displayed. 14) On «Engine Diagnosis» display, select {Dealer Check Mode Procedure}. 15) When the «Perform Inspection (Dealer Check) Mode?» is shown on the screen, click the [Next] button. 16) Perform subsequent procedures as instructed on the display screen. • If trouble still remains in the memory, the corresponding DTC appears on the display screen. NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”.

• Release the parking brake. • The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When engine control system diagnosis is finished, perform the VDC memory clearance procedure of self-diagnosis function.

EN(H4DOTC)(diag)-47

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Inspection Mode ENGINE (DIAGNOSTICS)

3. GENERAL SCAN TOOL 1) Check that no DTC remains after clearing memory. 2) Warm up the engine. 3) Install the delivery (test) mode fuse (A) of the main fuse box.

9) Using the general scan tool, check for DTC and record the result(s). NOTE: • For detailed operation procedures, refer to the general scan tool operation manual. • For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”.

(A)

EN-07555

4) Connect the general scan tool to the data link connector located in the lower portion of the instrument panel (on the driver’s side). CAUTION: Do not connect any scan tools except Subaru Select Monitor or general scan tool.

EN-07712

5) Start the engine. NOTE: Depress the clutch pedal when starting engine. 6) Turn the neutral position switch to ON by operating shift lever. 7) Keep the engine speed in 2,500 — 3,000 rpm range for 40 seconds. 8) Place the shift lever in 1st gear and drive the vehicle at 5 to 10 km/h (3 to 6 MPH). NOTE: • For AWD model, release the parking brake. • The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When engine control system diagnosis is finished, perform the VDC memory clearance procedure of self-diagnosis function.

EN(H4DOTC)(diag)-48

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Drive Cycle ENGINE (DIAGNOSTICS)

12.Drive Cycle A: PROCEDURE It is necessary to perform the drive cycle listed below if DTC is not found in the Inspection Mode. It is possible to complete diagnosis of the DTC by performing the indicated drive cycle. After the repair for the DTC, perform a necessary drive cycle and make sure the function recovers and the DTC is recorded.

1. PREPARATION FOR DRIVE CYCLE 1) Check that the battery voltage is 12 V or more and fuel remains approx. half [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8 Imp gal)]. 2) After performing the diagnostics and Clear Memory Mode, check that no DTC remains. 3) Check the delivery (test) mode fuse is removed. NOTE: • Perform the drive cycle after warming up the engine except when the engine coolant temperature at engine start is specified. • Perform the drive cycle twice if the DTC in the list is marked with *. After completing the first drive cycle, stop the engine and perform second diagnosis in same condition.

EN(H4DOTC)(diag)-49

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Drive Cycle ENGINE (DIAGNOSTICS)

2. DRIVE CYCLE A DTC

Item

Condition Engine coolant temperature at engine start is less than 20°C (68°F). —

*P0125

Insufficient Coolant Temperature for Closed Loop Fuel Control

*P0126

Insufficient Engine Coolant Temperature for Stable Operation

*P0128

Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature)

*P0133 *P0141

O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) O2 Sensor Heater Circuit (Bank1 Sensor2)

*P0171

System Too Lean (Bank 1)

Complete diagnosis with drive cycle B or C as well.

*P0172

System Too Rich (Bank 1)

Complete diagnosis with drive cycle B or C as well.

*P0301

Cylinder 1 Misfire Detected

Complete diagnosis with drive cycle B or C as well.

*P0302

Cylinder 2 Misfire Detected

*P0303

Cylinder 3 Misfire Detected

*P0304

Cylinder 4 Misfire Detected

*P0420

Catalyst System Efficiency Below Threshold (Bank 1)

*P0442

Evaporative Emission Control System Leak Detected (Small Leak)

*P0451

Evaporative Emission Control System Pressure Sensor

*P0456

Evaporative Emission Control System Leak Detected (Very Small Leak)

*P0457

Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off)

*P0459 P1443

Evaporative Emission System Purge Control Valve Circuit High Vent Control Solenoid Valve Function Problem

*P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

Complete diagnosis with drive cycle B or C as well.

*P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

Complete diagnosis with drive cycle B or C as well.

Engine coolant temperature at engine start is less than 55°C (131°F). — —

Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well.

Diagnostic procedure: 1) Drive for 20 minutes at a constant speed of 80 km/h (50 MPH). 2) Stop the vehicle and idle for one minute.

EN(H4DOTC)(diag)-50

Complete diagnosis with drive cycle B or C as well. — Engine coolant temperature at engine start is less than 25°C (77°F). — Engine coolant temperature at engine start is less than 25°C (77°F). Engine coolant temperature at engine start is less than 25°C (77°F). — —

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Drive Cycle ENGINE (DIAGNOSTICS)

3. DRIVE CYCLE B DTC

Item

Condition Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well.

*P0171

System Too Lean (Bank 1)

*P0172

System Too Rich (Bank 1)

*P0301

Cylinder 1 Misfire Detected

*P0302

Cylinder 2 Misfire Detected

Complete diagnosis with drive cycle A or C as well.

*P0303

Cylinder 3 Misfire Detected

Complete diagnosis with drive cycle A or C as well.

*P0304

Cylinder 4 Misfire Detected

*P0464 *P0506 *P0507

Fuel Level Sensor Circuit Intermittent Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected

*P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

Complete diagnosis with drive cycle A or C as well.

*P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

Complete diagnosis with drive cycle A or C as well.

Complete diagnosis with drive cycle A or C as well. — — —

Diagnostic procedure: 1) Drive at 10 km/h (6 MPH) or more. 2) Stop the vehicle and idle for ten minutes.

4. DRIVE CYCLE C DTC *P0030 *P0068 *P0101

Item HO2S Heater Control Circuit (Bank 1 Sensor 1) MAP/MAF - Throttle Position Correlation Mass or Volume Air Flow Circuit Range/Performance

Condition — — —

P0134 *P0139

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)

*P0171

System Too Lean (Bank 1)

*P0172

System Too Rich (Bank 1)

P0244 P0246

Turbo/Super Charger Wastegate Solenoid “A” Range/Performance Turbo/Super Charger Wastegate Solenoid “A” High

*P0301

Cylinder 1 Misfire Detected

Complete diagnosis with drive cycle A or B as well.

*P0302

Cylinder 2 Misfire Detected

Complete diagnosis with drive cycle A or B as well.

*P0303

Cylinder 3 Misfire Detected

*P0304

Cylinder 4 Misfire Detected

P2004 P2005

Intake Manifold Runner Control Stuck Open (Bank 1) Intake Manifold Runner Control Stuck Open (Bank 2)

*P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

*P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

— — Complete diagnosis with drive cycle A or B as well.

EN(H4DOTC)(diag)-51

Complete diagnosis with drive cycle A or B as well. — —

Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. — — Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well.

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Drive Cycle ENGINE (DIAGNOSTICS)

Diagnostic procedure: Drive according to the drive pattern described below. (H)

(C)

97 (60)

(D) 64 (40)

(G)

(F)

(E)

(B)

(A) 0

50

100

(I)

150

EN-00842

(A) (B) (C)

Idle the engine for 10 seconds or more. Accelerate the vehicle to 97 km/h (60 MPH) within 20 seconds. Drive the vehicle at 97 km/h (60 MPH) for 20 seconds.

(D) (E) (F)

Decelerate the vehicle to 64 km/h (40 MPH) with throttle fully closed. Drive the vehicle at 64 km/h (40 MPH) for 20 seconds. Accelerate the vehicle to 97 km/h (60 MPH) within 10 seconds.

(G) (H)

Stop the vehicle with throttle fully closed. Vehicle speed km/h (MPH)

(I)

Sec.

5. DRIVE CYCLE D DTC *P0181

Item Fuel Temperature Sensor “A” Circuit Range/Performance

Condition —

NOTE: In drive cycle D, one drive cycle will be established when both the drift diagnosis and stuck diagnosis have completed. Diagnostic procedure: DRIFT DIAGNOSIS 1) Make sure of the items below before starting the engine. • Engine coolant temperature is less than 30°C (86°F). • Remaining fuel is 10 2 (2.6 US gal, 2.2 Imp gal) or more. • Battery voltage is 10.9 V or more. 2) Idle the engine until engine coolant temperature is at least 10°C (18°F) higher than it was when engine started. 3) After the engine has reached the state of procedure 2), idle the engine for another 5 minutes or more. STUCK DIAGNOSIS 1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. 3) Drive the vehicle for the distance equal to the fuel of 50 2 (13.2 US gal, 11 Imp gal). NOTE: • It is acceptable to drive the vehicle intermittently. • Do not disconnect the battery terminals during stuck diagnosis. (Data will be cleared by disconnecting the battery terminals.)

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Drive Cycle ENGINE (DIAGNOSTICS)

6. DRIVE CYCLE E DTC *P0461

Item Fuel Level Sensor “A” Circuit Range/Performance

Condition —

Diagnostic procedure: 1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. 3) Drive the vehicle for the distance equal to the fuel of 30 2 (7.9 US gal, 6.6 Imp gal). NOTE: • It is acceptable to drive the vehicle intermittently. • Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)

7. DRIVE CYCLE F DTC *P0111

Item Intake Air Temperature Sensor 1 Circuit Range/Performance

Condition —

Diagnostic procedure: 1) Make sure that the engine coolant temperature is less than 30°C (86°F). 2) Drive according to the drive pattern described below. (A)

(2)

(4)

(6)

80 km/h (50 MPH)

0

(3)

(5)

(7)

(B)

(1) EN-07588

(A)

Vehicle speed

(B)

Elapsed time

(1)

Idle the engine for 10 seconds after engine start. Drive for 8 minutes at a constant speed of 80 km/h (50 MPH). Stop the vehicle and idle for 30 seconds.

(4)

Drive for 30 seconds at a constant speed of 80 km/h (50 MPH). Stop the vehicle and idle for 30 seconds.

(2) (3)

(5)

(6) (7)

Drive for 30 seconds at a constant speed of 80 km/h (50 MPH). Stop the vehicle and idle for 30 seconds.

NOTE: • There is no given transition time between idling and cruising. • Driving at constant speed only on a downhill causes smaller engine load and may result in failure to obtain a right diagnostic result. • When the engine stops while performing drive cycle F, perform it again from the state of procedure 1).

EN(H4DOTC)(diag)-53

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Drive Cycle ENGINE (DIAGNOSTICS)

8. DRIVE CYCLE H *

DTC P1602

Item Control Module Programming Error

Condition —

Diagnostic procedure: 1) Perform the Clear Memory Mode. 2) With the ignition switch ON (engine OFF), read the engine coolant temperature, intake air temperature and fuel temperature. 3) If the values from step 2) satisfy the following two conditions, idle the engine for one minute.

Condition: | Engine coolant temperature — Intake air temperature | ≤ 5°C (41°F) | Engine coolant temperature — Fuel temperature | ≤ 2°C (36°F) NOTE: • If the conditions are not satisfied, turn the ignition switch to OFF and wait until the parameters are satisfied. • Do not move the shift lever from neutral position during idling.

EN(H4DOTC)(diag)-54

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Clear Memory Mode ENGINE (DIAGNOSTICS)

13.Clear Memory Mode A: OPERATION 1. SUBARU SELECT MONITOR NOTE: • Initial diagnosis of electronic throttle control is performed after memory clearance. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine. • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

2. GENERAL SCAN TOOL For procedures clearing memory using the general scan tool, refer to the general scan tool operation manual. NOTE: Initial diagnosis of electronic throttle control is performed after memory clearance. For this reason, start the engine after 10 seconds or more have elapsed since the ignition switch was turned to ON.

EN(H4DOTC)(diag)-55

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System Operation Check Mode ENGINE (DIAGNOSTICS)

14.System Operation Check Mode A: OPERATION CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. NOTE: For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

EN(H4DOTC)(diag)-56

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

15.Malfunction Indicator Light A: PROCEDURE 1. Activation of malfunction indicator light. ↓ 2. Malfunction indicator light does not come on. ↓ 3. Malfunction indicator light does not go off. ↓ 4. Malfunction indicator light does not blink. ↓ 5. Malfunction indicator light remains blinking.

EN(H4DOTC)(diag)-57

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

B: ACTIVATION OF MALFUNCTION INDICATOR LIGHT 1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light (A) in the combination meter illuminates. NOTE: If the malfunction indicator light does not illuminate, perform diagnostics of the malfunction indicator light circuit or the combination meter circuit.

3) If the diagnostic system detects a misfire which could damage the catalyst, the malfunction indicator light will blink at a cycle of 1 Hz. (1) (2) (3) (4) (6) (5) EN-01680

(1) (2) (3) (4) (5) (6)

CHECK ENGINE

CHECK ENGINE

(A) EN-07714

ON OFF Ignition switch ON Engine start Misfire start 1 second

4) Install the delivery (test) mode fuse (A) of main fuse box with ignition switch to OFF.

2) After starting the engine, the malfunction indicator light goes out. If it does not go off, any of the engine and emission control system has malfunction.

(A)

(1) (3) (4) (2) (3) (4)

EN-07555 (5) (6)

(1) No DTC (2) Trouble occurs (3) ON

EN-01679

(1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light illuminates. (2) After the engine starts, malfunction indicator light blinks in a cycle of 0.5 Hz. (During diagnosis)

(4) OFF (5) Ignition switch ON (6) Engine start

EN(H4DOTC)(diag)-58

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

(3) Malfunction indicator light blinks at a cycle of 3 Hz after diagnosis if there is no trouble. Malfunction indicator light illuminates if faulty. (1) (2) (4)

(3)

EN-01681

(1) (2) (3) (4)

ON OFF Ignition switch ON 1 second

EN(H4DOTC)(diag)-59

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON DIAGNOSIS: The malfunction indicator light circuit is open or shorted. TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), malfunction indicator light does not illuminate. WIRING DIAGRAM: IGNITION SWITCH

B72

BATTERY SBF-5

F/B No. 5 1

MAIN SBF

3

19

E

COMBINATION METER

6

i10

M/B DELIVERY (TEST) MODE FUSE No. 36 1

B138

2

* *

18

i3

B : B135

C : B136

1 2 3 4 5 6 7 8

C:

: TERMINAL No. OPTIONAL ARRANGEMENT

ECM

i10

B138

*

C4

B33

C34

B38

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

B38

B72

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

EN-07804

1

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 33 (+) — Chassis ground (–):

Check Is the voltage 10 V or more?

EN(H4DOTC)(diag)-60

Yes Go to step 5.

No Go to step 2.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

2

3

4

5

6

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. COMBINATION METER CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the combination meter. 3) Disconnect the connectors from ECM and combination meter. 4) Measure the resistance of harness between ECM and combination meter connector. Connector & terminal (B135) No. 33 — (i10) No. 6: CHECK FOR POOR CONTACT. Check for poor contact of combination meter connector.

Is there poor contact of combi- Repair the poor nation meter connector? contact of combination meter connector. CHECK HARNESS BETWEEN COMBINAIs the voltage 10 V or more? Replace the meter TION METER AND IGNITION SWITCH CONcase assembly of NECTOR. combination meter. 1) Turn the ignition switch to ON.

Connector & terminal (i10) No. 19 (+) — Chassis ground (–):

CHECK FOR POOR CONTACT. Check for poor connection by shaking or pulling ECM connector and harness. CHECK ECM CONNECTOR. Check the connection of ECM connector.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and combination meter connector • Poor contact of coupling connector Go to step 4.

Check the following item and repair if necessary. NOTE: • Blown-out of fuse (F/B No. 5) • Open circuit or short circuit to ground in harness of power supply circuit Go to step 6.

Does the malfunction indicator Repair the poor light illuminate? contact of ECM connector. Is the ECM connector correctly Replace the ECM. Repair the connecconnected?

EN(H4DOTC)(diag)-61

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF DIAGNOSIS: The malfunction indicator light circuit is shorted. TROUBLE SYMPTOM: Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select Monitor or general scan tool display. WIRING DIAGRAM: IGNITION SWITCH

B72

BATTERY SBF-5

F/B No. 5 1

MAIN SBF

3

19

E

COMBINATION METER

6

i10

M/B DELIVERY (TEST) MODE FUSE No. 36 1

B138

2

* *

18

i3

B : B135

C : B136

1 2 3 4 5 6 7 8

C:

: TERMINAL No. OPTIONAL ARRANGEMENT

ECM

i10

B138

*

C4

B33

C34

B38

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

B38

B72

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

EN-07804

1

Step CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Turn the ignition switch to ON.

Check Yes Does the malfunction indicator Repair the ground light illuminate? short circuit of harness between ECM and combination meter connector.

EN(H4DOTC)(diag)-62

No Replace the ECM.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • The delivery (test) mode fuse circuit is open. TROUBLE SYMPTOM: Malfunction indicator light does not blink during Inspection Mode. WIRING DIAGRAM: IGNITION SWITCH

B72

BATTERY SBF-5

F/B No. 5 1

MAIN SBF

3

19

E

COMBINATION METER

6

i10

M/B DELIVERY (TEST) MODE FUSE No. 36 1

B138

2

* *

18

i3

B : B135

1 2 3 4 5 6 7 8

C:

C : B136

: TERMINAL No. OPTIONAL ARRANGEMENT

ECM

i10

B138

*

C4

B33

C34

B38

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

B38

B72

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

EN-07804

EN(H4DOTC)(diag)-63

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator Go to step 2. CATOR LIGHT. light illuminate? 1) Turn the ignition switch to OFF. 2) Check the delivery (test) mode fuse is removed. 3) Turn the ignition switch to ON. (engine OFF)

No Repair the malfunction indicator light circuit. CHECK HARNESS BETWEEN ECM AND Does the malfunction indicator Repair the ground Go to step 3. COMBINATION METER CONNECTOR. light illuminate? short circuit of har1) Turn the ignition switch to OFF. ness between 2) Disconnect the connector from ECM. ECM and combi3) Turn the ignition switch to ON. nation meter connector. CHECK HARNESS BETWEEN ECM AND DE- Is the resistance less than 1 Ω? Go to step 4. Repair the harness LIVERY (TEST) MODE FUSE. and connector. 1) Turn the ignition switch to OFF. NOTE: 2) Install the delivery (test) mode fuse of the In this case, repair main fuse box. the following item: 3) Measure the resistance of harness between • Open circuit of ECM connectors. harness between Connector & terminal ECM and delivery (B136) No. 4 — (B136) No. 34: (test) mode fuse • Poor contact of joint connector CHECK FOR POOR CONTACT. Is there poor contact of ECM Repair the poor Replace the ECM. Check for poor contact of ECM connector. connector? contact of ECM

EN(H4DOTC)(diag)-64

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING DIAGNOSIS: The delivery (test) mode fuse circuit is shorted. TROUBLE SYMPTOM: Malfunction indicator light blinks when delivery (test) mode fuse is not connected. WIRING DIAGRAM: IGNITION SWITCH

B72

BATTERY SBF-5

F/B No. 5 1

MAIN SBF

3

19

E

COMBINATION METER

6

i10

M/B DELIVERY (TEST) MODE FUSE No. 36 1

B138

2

* *

18

i3

B : B135

C : B136

1 2 3 4 5 6 7 8

C:

: TERMINAL No. OPTIONAL ARRANGEMENT

ECM

i10

B138

*

C4

B33

C34

B38

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

B38

B72

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6

B:

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

EN-07804

1

Step CHECK DELIVERY (TEST) MODE FUSE. 1) Check the delivery (test) mode fuse is removed. 2) Turn the ignition switch to ON.

Check Yes Does the malfunction indicator Go to step 2. light blink?

EN(H4DOTC)(diag)-65

No System is normal. NOTE: Malfunction indicator light blinks when delivery (test) mode fuse is connected.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? CHASSIS GROUND TERMINAL. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B136) No. 34 — Chassis ground:

EN(H4DOTC)(diag)-66

Yes Repair the short circuit to ground in harness between ECM and delivery (test) mode fuse.

No Replace the ECM.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

16.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Check of the fuel amount ↓ 2. Inspection of starter motor circuit. ↓ 3. Inspection of ECM power supply and ground line. ↓ 4. Inspection of ignition control system. ↓ 5. Inspection of fuel pump circuit. ↓ 6. Inspection of fuel injector circuit.

EN(H4DOTC)(diag)-67

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

B: STARTER MOTOR CIRCUIT CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B72

IGNITION SWITCH F/B No. 21 6

BATTERY SBF-5 3

E

4

2

2

MAIN SBF

STARTER RELAY

STARTER MOTOR

2

3

1

B493

CLUTCH STROKE SENSOR (CLUTCH START SWITCH)

M

B501

B26

C16

1

B14

ECM B: B135

B72 1 2 3 4 5 6

B493 1 2 3 4

C: B136

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B501 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5

EN-07805

1 2

Step Check CHECK BATTERY. Is the voltage 12 V or more? Check the battery voltage. CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate?

EN(H4DOTC)(diag)-68

Yes Go to step 2. Go to step 3.

No Charge or replace the battery. Go to step 4.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step 3

CHECK DTC.

4

CHECK INPUT SIGNAL FOR STARTER MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from starter motor. 3) Depress the clutch pedal. 4) Turn the ignition switch to START. 5) Measure the voltage between the starter motor connector and the engine ground. Connector & terminal (B14) No. 1 (+) — Engine ground (–): CHECK INPUT SIGNAL FOR STARTER MOTOR. 1) Depress the clutch pedal. 2) Turn the ignition switch to START. 3) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B493) No. 3 (+) — Chassis ground (–): CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ignition switch. 3) Measure the voltage between ignition switch connector and chassis ground. Connector & terminal (B72) No. 3 (+) — Chassis ground (–): CHECK IGNITION SWITCH. Measure the resistance between ignition switch terminals after turning the ignition switch to START position. Terminals No. 2 — No. 3: No. 6 — No. 3:

5

6

7

Check Is DTC displayed?

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Is the voltage 10 V or more?

Check the starter motor.

Is the voltage 10 V or more?

Repair the open circuit of the harness between starter relay connector and starter motor.

Go to step 6.

Is the voltage 10 V or more?

Go to step 7.

Repair the power supply circuit.

Is the resistance less than 1 Ω? Go to step 8.

EN(H4DOTC)(diag)-69

No The circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 5.

Replace the ignition switch.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

8

9

10

11

12

13

Step Check CHECK INPUT VOLTAGE OF STARTER RE- Is the voltage 10 V or more? LAY. 1) Remove the starter relay. 2) Connect the connector to ignition switch. 3) Turn the ignition switch to START. 4) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B493) No. 4 (+) — Chassis ground (–): (B493) No. 2 (+) — Chassis ground (–):

Yes Go to step 9.

CHECK STARTER RELAY. Is the resistance less than 1 Ω? 1) Connect the battery to starter relay terminals No. 2 and No. 1. 2) Measure the resistance between starter relay terminals. Terminals No. 4 — No. 3: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and starter relay connector. Connector & terminal (B136) No. 16 — (B493) No. 3: CHECK ECM INPUT VOLTAGE. Is the voltage 10 V or more? 1) Install the starter relay. 2) Depress the clutch pedal. 3) Turn the ignition switch to START. 4) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 26 (+) — Chassis ground (–):

Go to step 10.

Go to step 11.

No Check the following item and repair if necessary. • Blown-out of fuse (F/B No. 21) • Open or short circuit to ground in harness between starter relay connector and ignition switch connector Replace the starter relay.

Repair the open circuit of harness between ECM and starter relay connector.

Check the ECM Go to step 12. power supply and ground line. Is the resistance less than 1 Ω? Go to step 13. Repair the open circuit of harness between ECM and clutch start switch connector.

CHECK HARNESS BETWEEN ECM AND CLUTCH START SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the clutch start switch connector. 3) Measure the resistance of harness between ECM and clutch start switch connector. Connector & terminal (B135) No. 26 — (B501) No. 1: CHECK INPUT VOLTAGE OF CLUTCH Is the voltage 10 V or more? START SWITCH. 1) Turn the ignition switch to START. 2) Measure the voltage between the clutch start switch connector and chassis ground. Connector & terminal (B501) No. 2 (+) — Chassis ground (–):

EN(H4DOTC)(diag)-70

Replace the clutch start switch.

Repair open or short circuit to ground in harness between starter relay and clutch start switch connector.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM) CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY M/B No. 16 4 3

M/B No. 12

1 2

B72

B220

IGNITION SWITCH

BATTERY

F/B No. 12

SBF-5 3

B13 C1 D7

C2 C30

1

MAIN SBF

A : B134

E

B : B135 ECM C : B136

37 36 40 35 34

D3 A6 A4 A3 D1

D : B137

B21 E2

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

1

36 49

37 44 50

38 45 51

A:

B72

B21

39 52

40 46 53

41 47 54

1 2 3 4 5 6

C:

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 D:

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B:

B134

5 6 14 15 16 25 26 27 33 34 35

B220

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

Step Check Yes CHECK MAIN RELAY. Is the resistance less than 1 Ω? Go to step 2. 1) Turn the ignition switch to OFF. 2) Remove the main relay. 3) Connect the battery to main relay terminals No. 1 and No. 2. 4) Measure the resistance between main relay terminals. Terminals No. 3 — No. 4:

EN(H4DOTC)(diag)-71

EN-07806

No Replace the main relay.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

2

3

4

5

6

Step Check Yes CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? Go to step 3. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 2 (+) — Chassis ground (–): (B136) No. 30 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF MAIN RELAY. Measure the voltage between main relay connector and chassis ground. Connector & terminal (B220) No. 1 (+) — Chassis ground (–): (B220) No. 4 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to OFF. 2) Install the main relay. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 13 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to OFF. 2) Connect the connector to ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 1 (+) — Chassis ground (–): (B137) No. 7 (+) — Chassis ground (–):

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and engine ground terminal • Poor contact of coupling connector Repair the open or ground short circuit of harness of power supply circuit.

Is the voltage 10 V or more?

Go to step 4.

Is the voltage 10 V or more?

Go to step 5.

Repair the open or ground short circuit of harness of power supply circuit.

Is the voltage 10 V or more?

Go to step 6.

Repair the open circuit in harness between ECM and main relay connector.

Is the voltage 10 V or more?

Check ignition control system.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and main relay connector • Poor contact of main relay connector • Poor contact of ECM connector

EN(H4DOTC)(diag)-72

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

D: IGNITION CONTROL SYSTEM CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

32

22

IGNITION SWITCH

MAIN SBF

F/B No. 12

SBF-5

B72

1

21

3

ECM

31

B134

10

31

9

49

20

B21

BATTERY

E2

E 2

1

E34 3

2

1

E33 3

2

1

E32 3

2

1

3

E31

E IGNITION COIL No. 1 E31

B134

B21

E32 E33 E34

1 2 3

IGNITION COIL No. 2

1 2 8 9 10 18 19 20 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

IGNITION COIL No. 3

IGNITION COIL No. 4

B72 1 2 3 4 5 6

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

EN-07807

1

Step CHECK SPARK PLUG CONDITION. 1) Remove the spark plug. 2) Check the spark plug condition.

Check Yes Is the spark plug condition nor- Go to step 2. mal?

EN(H4DOTC)(diag)-73

No Replace the spark plug.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

2

3

4

5

6

7

Step Check CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cylin1) Connect the spark plug to ignition coil. der? 2) Release the fuel pressure. 3) Contact the spark plug thread portion to engine. 4) While opening the throttle valve fully, crank the engine to check that spark occurs at each cylinder. CHECK IGNITION COIL POWER SUPPLY Is the voltage 10 V or more? CIRCUIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ignition coil. 3) Turn the ignition switch to ON. 4) Measure the voltage between ignition coil connector and engine ground. Connector & terminal (E31) No. 3 (+) — Engine ground (–): (E32) No. 3 (+) — Engine ground (–): (E33) No. 3 (+) — Engine ground (–): (E34) No. 3 (+) — Engine ground (–):

Yes No Check fuel pump Go to step 3. system.

Go to step 4.

CHECK HARNESS OF IGNITION COIL Is the resistance less than 5 Ω? Go to step 5. GROUND CIRCUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between ignition coil connector and engine ground. Connector & terminal (E31) No. 2 — Engine ground: (E32) No. 2 — Engine ground: (E33) No. 2 — Engine ground: (E34) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Ω? Go to step 6. NITION COIL CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and ignition coil connector. Connector & terminal (B134) No. 21 — (E31) No. 1: (B134) No. 22 — (E32) No. 1: (B134) No. 31 — (E33) No. 1: (B134) No. 32 — (E34) No. 1: CHECK HARNESS BETWEEN ECM AND IGNITION COIL CONNECTOR. Measure the resistance of harness between ECM and engine ground. Connector & terminal (B134) No. 21 — Engine ground: (B134) No. 22 — Engine ground: (B134) No. 31 — Engine ground: (B134) No. 32 — Engine ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Is the resistance 1 MΩ or more?

Go to step 7.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

EN(H4DOTC)(diag)-74

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in power supply circuit • Poor contact of coupling connector • Blown-out of fuse (F/B No. 12) Repair the open circuit in harness between ignition coil connector and engine grounding terminal.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and ignition coil connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and ignition coil connector.

Replace the ignition coil.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

E: FUEL PUMP CIRCUIT CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY M/B No. 20 14 i3

20 B38

21 FUEL PUMP RELAY

B220

2

i155 R333

8

E FUEL PUMP CONTROL UNIT

R333 4 1

2

1

R15

5

6 7

10

9

R122

R57

i155

10 4

i3

FUEL PUMP R58

C33 B10

6

5

B38

E

ECM

M

B: B135 C: B136

B220

R58

R122

1 2

1 2 3 4 5 6 7 8 9 10

C: B136

3 4 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

5 6

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

R57 1 3

i155

4 5 6 8 9 10 11

B: 2 7

B135

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

EN-07808

1

Step Check CHECK OPERATING SOUND OF FUEL Does the fuel pump emit operPUMP. ating sound? Make sure that the fuel pump operates for two seconds when turning the ignition switch to ON. NOTE: Fuel pump operation can be executed using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

EN(H4DOTC)(diag)-75

Yes Check the fuel injector circuit.

No Display the DTC.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

F: FUEL INJECTOR CIRCUIT CAUTION: • Check or repair only faulty parts. • After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

E

B220

13 51

12 52

11

ECM

53

54

48

10

B134

B21 E2

FUEL INJECTOR No. 1

E5

B21

B220

1 3 4 2

5 7 8 6

2

1

FUEL INJECTOR No. 4

FUEL INJECTOR No. 3

E17

1 2

E17

2

1

FUEL INJECTOR No. 2

E16

E6

E6

2

1

E16

2

1

E5

9 11 12 10

13 15 16 14

17 18 20 21 19

B134

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

41 47 54

EN-07809

1

Step Check CHECK OPERATION OF EACH FUEL INJEC- Does the fuel injector emit TOR. operating sound? While cranking the engine, check each fuel injector emits operating sound. Use a sound scope or attach a screwdriver to the injector for this check.

EN(H4DOTC)(diag)-76

Yes No Check the fuel Go to step 2. pressure.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

2

Step Check CHECK POWER SUPPLY TO EACH FUEL IN- Is the voltage 10 V or more? JECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector. 3) Turn the ignition switch to ON. 4) Measure the voltage between fuel injector connector and the engine ground. Connector & terminal #1 (E5) No. 1 (+) — Engine ground (–): #2 (E16) No. 1 (+) — Engine ground (–): #3 (E6) No. 1 (+) — Engine ground (–): #4 (E17) No. 1 (+) — Engine ground (–):

Yes Go to step 3.

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FUEL INJECTOR CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and fuel injector connector. Connector & terminal #1 (B134) No. 10 — (E5) No. 2: #2 (B134) No. 11 — (E16) No. 2: #3 (B134) No. 12 — (E6) No. 2: #4 (B134) No. 13 — (E17) No. 2:

4

CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal #1 (B134) No. 10 — Chassis ground: #2 (B134) No. 11 — Chassis ground: #3 (B134) No. 12 — Chassis ground: #4 (B134) No. 13 — Chassis ground: CHECK EACH FUEL INJECTOR. Measure the resistance between each fuel injector terminals. Terminals No. 1 — No. 2: CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

5

6

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between main relay and fuel injector connector • Poor contact of main relay connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel injector connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and fuel injector connector.

Is the resistance 1 MΩ or more?

Go to step 5.

Is the resistance 5 — 20 Ω?

Go to step 6.

Replace the faulty fuel injector.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

Inspection using “General Diagnostic Table”.

EN(H4DOTC)(diag)-77

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

17.List of Diagnostic Trouble Code (DTC) A: LIST DTC P0011

P0014

Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Exhaust AVCS System 1 (Range/ Performance)

P0016

Crankshaft Position - Camshaft Position Correlation (Bank1)

P0017

Crank and Cam Timing B System Failure (Bank 1)

P0018

Crankshaft Position - Camshaft Position Correlation (Bank2)

P0019

Crank and Cam Timing B System Failure (Bank 2)

P0021

Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 2) Exhaust AVCS System 2 (Range/ Performance)

P0024

P0030

HO2S Heater Control Circuit (Bank 1 Sensor 1)

P0031

HO2S Heater Control Circuit Low (Bank 1 Sensor 1)

P0032

HO2S Heater Control Circuit High (Bank 1 Sensor 1)

P0037

HO2S Heater Control Circuit Low (Bank 1 Sensor 2)

P0038

HO2S Heater Control Circuit High (Bank 1 Sensor 2)

P0068

MAP/MAF - Throttle Position Correlation

P0101

Mass or Volume Air Flow Circuit Range/Performance

P0102

Mass or Volume Air Flow Circuit Low Input

P0103

Mass or Volume Air Flow Circuit High Input

Index











EN(H4DOTC)(diag)-78

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0107

Item Manifold Absolute Pressure/Barometric Pressure Circuit Low Input

P0108

Manifold Absolute Pressure/Barometric Pressure Circuit High Input

P0111

Intake Air Temperature Sensor 1 Circuit Range/Performance

P0112

Intake Air Temperature Sensor 1 Circuit Low

P0113

Intake Air Temperature Sensor 1 Circuit High

P0117

Engine Coolant Temperature Circuit Low

P0118

Engine Coolant Temperature Circuit High

P0122

Throttle/Pedal Position Sensor/ Switch “A” Circuit Low

P0123

Throttle/Pedal Position Sensor/ Switch “A” Circuit High

P0125

Insufficient Coolant Temperature for Closed Loop Fuel Control

P0126

Insufficient Engine Coolant Temperature for Stable Operation

P0128

Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature)

P0131

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)

P0132

O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)

P0133

O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)

P0134

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)

P0137

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)

P0138

O2 Sensor Circuit High Voltage (Bank 1 Sensor 2)

Index













EN(H4DOTC)(diag)-79

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0139

P0140

P0141

P0171 P0172 P0181

P0182

P0183

P0222

P0223

P0230 P0244

P0245

P0246

P0301 P0302 P0303 P0304 P0327

P0328

P0335

Item O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)

Index

O2 Sensor Circuit No Activity

O2 Sensor Heater Circuit (Bank1

System Too Lean (Bank 1)

System Too Rich (Bank 1)

Fuel Temperature Sensor “A” Cir Fuel Temperature Sensor “A” Cir Fuel Temperature Sensor “A” Cir Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Fuel Pump Primary Circuit

Turbo/Super Charger Wastegate

Turbo/Super Charger Wastegate

Turbo/Super Charger Wastegate

Cylinder 1 Misfire Detected

Cylinder 2 Misfire Detected

Cylinder 3 Misfire Detected

Cylinder 4 Misfire Detected

Knock Sensor 1 Circuit Low (Bank Knock Sensor 1 Circuit High (Bank Crankshaft Position Sensor “A” Cir-

EN(H4DOTC)(diag)-80

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0336

P0340

P0345

P0365

P0390

P0420

P0442

P0447

P0448

P0451

P0452

P0453

P0456

P0457

P0458

Item Index Crankshaft Position Sensor “A” Cir- Camshaft Position Sensor “A” Cir- Camshaft Position Sensor “A” Cir- Camshaft Position Sensor “B” Cir- Camshaft Position Sensor “B” Cir- Catalyst System Efficiency Below

Evaporative Emission Control Sys- Evaporative Emission Control Sys- Evaporative Emission Control Sys- Evaporative Emission Control Sys- Evaporative Emission Control Sys- Evaporative Emission Control Sys- Evaporative Emission Control System Leak Detected (Very Small Leak) Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) Evaporative Emission System Purge Control Valve Circuit Low

P0459

Evaporative Emission System Purge Control Valve Circuit High

P0461

Fuel Level Sensor “A” Circuit Range/Performance

P0462

Fuel Level Sensor “A” Circuit Low

P0463

Fuel Level Sensor “A” Circuit High





EN(H4DOTC)(diag)-81

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0464

Item Fuel Level Sensor Circuit Intermittent

P0500

Vehicle Speed Sensor “A”

P0506

Idle Air Control System RPM Lower Than Expected

P0507

Idle Air Control System RPM Higher Than Expected

P0512

Starter Request Circuit

P0513

Incorrect Immobilizer Key

P0604

Internal Control Module Random Access Memory (RAM) Error

P0605

Internal Control Module Read Only Memory (ROM) Error

P0607

Throttle Control System Circuit Range/Performance

P0638

Throttle Actuator Control Range/ Performance (Bank 1)

P0851

Neutral Switch Input Circuit Low (MT Model)

P0852

Neutral Switch Input Circuit High (MT Model)

P1152

O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1)

P1153

O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1)

P1160

Return Spring Failure

P1400

Fuel Tank Pressure Control Solenoid Valve Circuit Low

P1420

Fuel Tank Pressure Control Sol. Valve Circuit High

P1443

Vent Control Solenoid Valve Function Problem

P1518

Starter Switch Circuit Low Input

P1560

Back-Up Voltage Circuit Malfunction

Index













EN(H4DOTC)(diag)-82

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P1570 P1571 P1572

P1574 P1576 P1577 P1578 P1602

P2004

P2005

P2006

P2007

P2008

P2009

P2011

P2012

P2016

P2017

P2021

P2022

Item

Index

Reference Code Incompatibility

IMM Circuit Failure

Key Communication Failure

EGI Control Module EEPROM

IMM Control Module EEPROM

Meter Failure

Control Module Programming Error Intake Manifold Runner Control

Intake Manifold Runner Control

Intake Manifold Runner Control

Intake Manifold Runner Control

Intake Manifold Runner Control

Intake Manifold Runner Control

Intake Manifold Runner Control

Intake Manifold Runner Control

Intake Manifold Runner Position

Intake Manifold Runner Position

Intake Manifold Runner Position

Intake Manifold Runner Position

2) Antenna

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P2088

P2089

P2090

P2091

P2092

P2093

P2094

P2095

P2096

P2097

P2101

P2102

P2103

P2109

P2122

P2123

P2127

P2128

P2135

Item Intake Camshaft Position Actuator Control Circuit Low (Bank 1)

Index

Intake Camshaft Position Actuator Exhaust Camshaft Position Actua- Exhaust Camshaft Position Actua- Intake Camshaft Position Actuator Intake Camshaft Position Actuator Exhaust Camshaft Position Actua- Exhaust Camshaft Position Actua- Post Catalyst Fuel Trim System

Post Catalyst Fuel Trim System

Throttle Actuator Control Motor Cir- Throttle Actuator Control Motor Cir- Throttle Actuator Control Motor Cir- Throttle/Pedal Position Sensor “A” Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P2138

Item Throttle/Pedal Position Sensor/ Switch “D”/“E” Voltage Correlation

P2227

Atmospheric Pressure Sensor Range/Performance

P2228

Barometric Pressure Circuit Low

P2229

Barometric Pressure Circuit High

P2419

Evaporative Emission System Switching Valve Control Circuit Low Evaporative Emission System Switching Valve Control Circuit High

P2420

U0073

CAN Failure, Bus ‘OFF’ Detection

U0101

CAN (TCU) Data not Loaded

U0122

CAN (VDC) Data not Loaded

U0140

CAN (BCU) Data not Loaded

U0402

CAN (TCU) Data Abnormal

U0416

CAN (VDC) Data Abnormal

U0422

CAN (BCU) Data Abnormal

Index









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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

18.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Check the AVCS system operating angle using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the AVCS system operating angle approximately 0°?

Yes Go to step 2.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft)

When the oil flow control solenoid valve duty output exceeds 10%, is the AVCS system operating angle approx. 0°?

Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft)

Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

EN(H4DOTC)(diag)-86

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

B: DTC P0014 EXHAUST AVCS SYSTEM 1 (RANGE/PERFORMANCE) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Check the exhaust AVCS system operating angle using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the exhaust AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Yes Go to step 2. Is the exhaust AVCS system operating angle approximately 0°?

When the oil flow control solenoid valve duty output exceeds 10%, is the exhaust AVCS system operating angle approx. 0°?

EN(H4DOTC)(diag)-87

Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft)

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft) Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

C: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the AVCS system operating angle approx. 0°, and oil flow control solenoid valve duty output approx. 10%?

EN(H4DOTC)(diag)-88

Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft) • Timing belt (matching of timing mark)

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

D: DTC P0017 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the exhaust AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the exhaust AVCS system operating angle approx. 0°, and oil flow control solenoid valve duty output approx. 10%?

EN(H4DOTC)(diag)-89

Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft) • Timing belt (matching of timing mark)

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

E: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the AVCS system operating angle approx. 0°, and oil flow control solenoid valve duty output approx. 10%?

EN(H4DOTC)(diag)-90

Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft) • Timing belt (matching of timing mark)

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

F: DTC P0019 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the exhaust AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the exhaust AVCS system operating angle approx. 0°, and oil flow control solenoid valve duty output approx. 10%?

EN(H4DOTC)(diag)-91

Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft) • Timing belt (matching of timing mark)

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

G: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Check the AVCS system operating angle using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the AVCS system operating angle approximately 0°?

Yes Go to step 2.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft)

When the oil flow control solenoid valve duty output exceeds 10%, is the AVCS system operating angle approx. 0°?

Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft)

Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

EN(H4DOTC)(diag)-92

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

H: DTC P0024 EXHAUST AVCS SYSTEM 2 (RANGE/PERFORMANCE) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Check the exhaust AVCS system operating angle using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the exhaust AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Yes Go to step 2. Is the exhaust AVCS system operating angle approximately 0°?

When the oil flow control solenoid valve duty output exceeds 10%, is the exhaust AVCS system operating angle approx. 0°?

EN(H4DOTC)(diag)-93

Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft)

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft) Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

I:

DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2 B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

D3

C: B136

37

*

7

E3 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07810

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Start and warm up the engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 4) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 5 — (E24) No. 2: (B136) No. 6 — (E24) No. 2: (B136) No. 19 — (E24) No. 3: (B136) No. 18 — (E24) No. 4: Is the resistance less than 2 — Go to step 3. CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen 3 Ω? (A/F) sensor connector terminals. Terminals No. 1 — No. 2:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector

Replace the front oxygen (A/F) sensor. CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact of ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

J: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2 B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

D3

C: B136

37

*

7

E3 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07810

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY TO FRONT OXY- Is the voltage 10 V or more? GEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between front oxygen (A/F) sensor connector and engine ground. Connector & terminal (E24) No. 1 (+) — Engine ground (–):

Yes Go to step 2.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 5 — (E24) No. 2: (B136) No. 6 — (E24) No. 2:

3

CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

Is the resistance less than 5 Ω? Go to step 4.

4

CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen (A/F) sensor terminals. Terminals No. 1 — No. 2:

Is the resistance 2 — 3 Ω?

EN(H4DOTC)(diag)-97

Repair the poor contact of ECM connector.

No Repair the power supply line. NOTE: In this case, repair the following item: • Open circuit in harness between A/F, oxygen sensor relay and front oxygen (A/F) sensor connector • Poor contact of A/F, oxygen sensor relay connector • Poor contact of coupling connector • Fault of A/F, oxygen sensor relay Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Replace the front oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

K: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2 B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

D3

C: B136

37

*

7

E3 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07810

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 5 (+) — Chassis ground (–): (B136) No. 6 (+) — Chassis ground (–): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? 1) Disconnect the connector from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

EN(H4DOTC)(diag)-99

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector.

Repair the poor contact of ECM connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

L: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B83

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

E25

B503

12 11 B22

E3

B220

2

10

1 2 3 4

1 2 3 4 5 6 7 8

16

9

E

B220

5 7 8 6

1 3 4 2

REAR OXYGEN SENSOR

13 15 16 14

9 11 12 10

17 18 20 21 19

E25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3

1

4

B21

34 42 48

10

9

15

E3 B22

E

B6

C20 C9

* * B30

* * B83

B503

A: B134 ECM C: B136

D1 34

A3

A4

A6

49

37 44 50

38 45 51

39 52

B22

1 5 9 13

2 6 10 14

3 7 11 15

40 46 53

41 47 54

A: B134

4 8 12 16

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B: B135

C: B136

35

40

36

D3

D: B137

37

*

36

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B: B135 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07811

EN(H4DOTC)(diag)-100

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY TO REAR OXYIs the voltage 10 V or more? GEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and engine ground. Connector & terminal (E25) No. 2 (+) — Engine ground (–):

Yes Go to step 2.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 6 — (E25) No. 1:

3

CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

Is the resistance less than 5 Ω? Go to step 4.

4

CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor terminals. Terminals No. 1 — No. 2:

Is the resistance 5 — 7 Ω?

EN(H4DOTC)(diag)-101

Repair the poor contact of ECM connector.

No Repair the power supply line. NOTE: In this case, repair the following item: • Open circuit in harness between A/F, oxygen sensor relay and rear oxygen sensor connector • Poor contact of A/F, oxygen sensor relay connector • Poor contact of coupling connector • Fault of A/F, oxygen sensor relay Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Replace the rear oxygen sensor.

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

M: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B83

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

E25

B503

12 11 B22

E3

B220

2

10

1 2 3 4

1 2 3 4 5 6 7 8

16

9

E

B220

5 7 8 6

1 3 4 2

REAR OXYGEN SENSOR

13 15 16 14

9 11 12 10

17 18 20 21 19

E25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3

1

4

B21

34 42 48

10

9

15

E3 B22

E

B6

C20 C9

* * B30

* * B83

B503

A: B134 ECM C: B136

D1 34

A3

A4

49

37 44 50

38 45 51

39 52

B22

1 5 9 13

2 6 10 14

3 7 11 15

40 46 53

41 47 54

A: B134

4 8 12 16

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B: B135

C: B136

35

40

36

37

A6

D: B137 D3

*

36

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B: B135 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07811

1

Step CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 6 (+) — Chassis ground (–):

Check Is the voltage 10 V or more?

EN(H4DOTC)(diag)-102

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and rear oxygen sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check Yes CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? Repair the poor 1) Disconnect the connector from ECM. contact of ECM 2) Measure the resistance between ECM and connector. chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

EN(H4DOTC)(diag)-103

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

N: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MANIFOLD ABSOLUTE PRESSURE SENSOR

E21

1 2 3

1 2 3

E21 B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

A: B134 1 8 9 18 19 28 29

6 23 28

E2 B21

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D: B137

A29 D20 A19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

A: B134 ECM D: B137

EN-07667

1

Step CHECK AIR INTAKE SYSTEM.

Check Are there holes, loose bolts or disconnection of hose on air intake system?

EN(H4DOTC)(diag)-104

Yes Repair the air intake system.

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

4

Step CHECK MANIFOLD ABSOLUTE PRESSURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the shift lever in neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of intake manifold pressure sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the “General Scan Tool Instruction Manual”. CHECK THROTTLE OPENING ANGLE. Read the data of throttle position signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the “General Scan Tool Instruction Manual”. CHECK THROTTLE OPENING ANGLE.

Check Yes Is the measured value 73.3 — Go to step 3. 106.6 kPa (550 — 800 mmHg, 21.65 — 31.50 inHg) when the ignition is turned ON, and 20.0 — 46.7 kPa (150 — 350 mmHg, 5.91 — 13.78 inHg) during idling?

No Replace the manifold absolute pressure sensor.

Is the measured value less than Go to step 4. 5% when throttle is fully closed?

Replace the electronic throttle control.

Is the measured value 85% or more when throttle is fully open?

Replace the electronic throttle control.

EN(H4DOTC)(diag)-105

Replace the manifold absolute pressure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

O: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

5

4

1

C22

C11

C31

2

B3

* *

C10

B30

B83

* B: B135 C: B136

B3 1 2 3 4 5

ECM

B220

1 3 4 2

5 7 8 6

9 11 12 10

: TERMINAL No. OPTIONAL ARRANGEMENT

B: B135

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

B83

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

EN-07812

EN(H4DOTC)(diag)-106

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H4DOTC)(diag)-107

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the mass air flow and intake air temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

P: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

4 C11

1

5 C22

2

B3

* *

C31

C10

B30

B83

* B: B135 C: B136

B3 1 2 3 4 5

B220

1 3 4 2

5 7 8 6

9 11 12 10

: TERMINAL No. OPTIONAL ARRANGEMENT

ECM

B: B135

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

B83

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

EN-07812

EN(H4DOTC)(diag)-108

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the voltage less than 0.2 V? Go to step 2. 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK POWER SUPPLY OF MASS AIR Is the voltage 10 V or more? FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from mass air flow and intake air temperature sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 3 (+) — Engine ground (–):

3

CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and the mass air flow and intake air temperature sensor connector. Connector & terminal (B136) No. 22 — (B3) No. 5: CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 22 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM and mass air flow and intake air temperature sensor connector.

4

5

Go to step 3.

Is the resistance less than 1 Ω? Go to step 4.

Is the resistance 1 MΩ or more?

Is there poor contact of the ECM or the mass air flow and intake air temperature sensor connector?

EN(H4DOTC)(diag)-109

Go to step 5.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between main relay and mass air flow and intake air temperature sensor connector • Poor contact of main relay connector Repair the open circuit of harness between the ECM and mass air flow and intake air temperature sensor connector.

Repair the ground short circuit of harness between ECM and mass air flow and intake air temperature sensor connector. Repair the poor Replace the mass contact of ECM or air flow and intake mass air flow and air temperature intake air tempera- sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

Q: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

4 C11

1

5 C22

2

B3

* *

C31

C10

B30

B83

* B: B135 C: B136

B3 1 2 3 4 5

B220

1 3 4 2

5 7 8 6

9 11 12 10

: TERMINAL No. OPTIONAL ARRANGEMENT

ECM

B: B135

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

B83

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

EN-07812

EN(H4DOTC)(diag)-110

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check CHECK CURRENT DATA. Is the voltage 5 V or more? 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Yes Go to step 2.

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from mass air flow and intake air temperature sensor. 3) Start the engine. 4) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 4 — Engine ground:

Repair the short circuit of harness to power supply between ECM and mass air flow and intake air temperature sensor connector.

CHECK FOR POOR CONTACT. Check for poor contact of mass air flow and intake air temperature sensor connector.

Go to step 4.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and mass air flow and intake air temperature sensor connector. • Poor contact of ECM connector Is there poor contact in the Repair any poor Replace the mass mass air flow and intake air contact of the air flow and intake temperature sensor connector? mass air flow and air temperature intake air tempera- sensor.

EN(H4DOTC)(diag)-111

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

R: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MANIFOLD ABSOLUTE PRESSURE SENSOR

E21

1 2 3

1 2 3

E21 B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

A: B134

6 23 28

E2 B21

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D: B137

A29 D20 A19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

A: B134 ECM D: B137

EN-07667

EN(H4DOTC)(diag)-112

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the measured value less than Go to step 2. 1) Start the engine. 13.3 kPa (100 mmHg, 3.94 2) Read the data of intake manifold absolute inHg)? pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK POWER SUPPLY OF MANIFOLD ABSOLUTE PRESSURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 3 (+) — Engine ground (–):

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and manifold absolute pressure sensor connector. Connector & terminal (B137) No. 20 — (E21) No. 2:

4

CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 20 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM and manifold absolute pressure sensor connector.

5

Is the voltage 4.5 V or more?

Is the resistance 1 MΩ or more?

Go to step 3.

Go to step 5.

Is there poor contact of ECM or Repair the poor manifold absolute pressure contact of ECM or manifold absolute sensor connector? pressure sensor connector.

EN(H4DOTC)(diag)-113

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and manifold absolute pressure sensor connector. • Poor contact of ECM connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and manifold absolute pressure sensor connector. • Poor contact of coupling connector Repair ground short circuit of harness between ECM and manifold absolute pressure sensor connector. Replace the manifold absolute pressure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

S: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MANIFOLD ABSOLUTE PRESSURE SENSOR

E21

1 2 3

1 2 3

E21 B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

A: B134

6 23 28

E2 B21

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D: B137

A29 D20 A19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

A: B134 ECM D: B137

EN-07667

EN(H4DOTC)(diag)-114

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Go to step 2. Is the measured value 119.5 1) Start the engine. kPa (896.5 mmHg, 35.29 inHg) 2) Read the data of intake manifold absolute or more? pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Start the engine. 4) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 1 — Engine ground:

Is the measured value 119.5 Repair the short kPa (896.5 mmHg, 35.29 inHg) circuit of harness or more? to power supply between ECM and manifold absolute pressure sensor connector.

CHECK FOR POOR CONTACT. Check for poor contact of manifold absolute pressure sensor connector.

Is there poor contact of manifold absolute pressure sensor connector?

Is the resistance less than 5 Ω? Go to step 4.

EN(H4DOTC)(diag)-115

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and manifold absolute pressure sensor connector. • Poor contact of ECM connector • Poor contact of coupling connector Repair the poor Replace the manicontact of manifold absolute presfold absolute pres- sure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

T: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

5

4

1

C22

C11

C31

2

B3

* *

C10

B30

B83

* B: B135 C: B136

B3 1 2 3 4 5

ECM

B220

1 3 4 2

5 7 8 6

9 11 12 10

: TERMINAL No. OPTIONAL ARRANGEMENT

B: B135

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

B83

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

EN-07812

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK ENGINE COOLANT TEMPERAIs the temperature 75°C TURE. (167°F) or more? 1) Start the engine and warm up completely. 2) Measure the engine coolant temperature using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H4DOTC)(diag)-117

Yes Replace the mass air flow and intake air temperature sensor.

No Go to DTC P0125.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

U: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

4 C11

1

5 C22

2

B3

* *

C31

C10

B30

B83

* B: B135 C: B136

B3 1 2 3 4 5

B220

1 3 4 2

5 7 8 6

9 11 12 10

: TERMINAL No. OPTIONAL ARRANGEMENT

ECM

B: B135

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

B83

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

EN-07812

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the intake air temperature 1) Start the engine. 120°C (248°F) or more? 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Yes Go to step 2.

CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or MASS AIR FLOW AND INTAKE AIR TEMmore? PERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and mass air flow and intake air temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 31 — Chassis ground:

Replace the mass air flow and intake air temperature sensor.

EN(H4DOTC)(diag)-119

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the ground short circuit of harness between ECM and mass air flow and intake air temperature sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

V: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16 4 3

3

2 1 B220

E

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

4 C11

1

5 C22

2

B3

* *

C31

C10

B30

B83

* B: B135 C: B136

B3 1 2 3 4 5

B220

1 3 4 2

5 7 8 6

9 11 12 10

: TERMINAL No. OPTIONAL ARRANGEMENT

ECM

B: B135

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

B83

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

EN-07812

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check CHECK CURRENT DATA. Is the intake air temperature 1) Start the engine. less than –40°C (–40°F)? 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK FOR POOR CONTACT. Check for poor contact of ECM and mass air flow and intake air temperature sensor connector.

Is there poor contact of the ECM or the mass air flow and intake air temperature sensor connector?

Yes Go to step 2.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the poor contact of ECM or mass air flow and intake air temperature sensor connector. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. Repair the harness MASS AIR FLOW AND INTAKE AIR TEMand connector. PERATURE SENSOR CONNECTOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connector from ECM and the following item: mass air flow and intake air temperature sensor. • Open circuit in 3) Measure the resistance of harness between harness between ECM and the mass air flow and intake air temECM and mass air perature sensor connector. flow and intake air Connector & terminal temperature sen(B136) No. 31 — (B3) No. 1: sor connector. (B135) No. 30 — (B3) No. 2: • Poor contact of coupling connector CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? Repair the short Replace the mass MASS AIR FLOW AND INTAKE AIR TEMcircuit of harness air flow and intake PERATURE SENSOR CONNECTOR. to power supply air temperature 1) Connect all connectors. between ECM and sensor. (B136) No. 31 (+) — Chassis ground (–):

EN(H4DOTC)(diag)-121

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

W: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

E8

ENGINE COOLANT TEMPERATURE SENSOR

1 2

2 1

E8

A: B134 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

12 6

E2 B21

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

D22 A29

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

A: B134 ECM D: B137

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the temperature 150°C 1) Start the engine. (302°F) or more? 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND EN- Is the resistance 1 MΩ or GINE COOLANT TEMPERATURE SENSOR more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and engine coolant temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 22 — Chassis ground:

EN(H4DOTC)(diag)-123

Yes Go to step 2.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Replace the Repair short cirengine coolant cuit in harness to temperature sen- ground between sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

X: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

E8

ENGINE COOLANT TEMPERATURE SENSOR

1 2

2 1

E8

A: B134 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

12 6

E2 B21

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

D22 A29

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

A: B134 ECM D: B137

EN-07668

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Is the engine coolant tempera- Go to step 2. 1) Start the engine. ture less than –40°C (–40°F)? 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Check for poor contact of ECM and engine cool- engine coolant temperature contact of ECM or ant temperature sensor connector. sensor connector? engine coolant temperature sensor connector. CHECK HARNESS BETWEEN ECM AND EN- Is the resistance less than 1 Ω? Go to step 4. GINE COOLANT TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and engine coolant temperature sensor. 3) Measure the resistance of harness between ECM and engine coolant temperature sensor connector. Connector & terminal (B137) No. 22 — (E8) No. 2: (B134) No. 29 — (E8) No. 1: CHECK HARNESS BETWEEN ECM AND EN- Is the voltage 5 V or more? GINE COOLANT TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 22 (+) — Chassis ground (–):

EN(H4DOTC)(diag)-125

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and engine coolant temperature sensor connector • Poor contact of coupling connector Repair the short Replace the circuit of harness engine coolant to power supply temperature senbetween ECM and sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

Y: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13

B220

M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B17

B7

B220

ECM

E

A28

D: B137

C4

C: B136

A18

B: B135

A19 A1 A2 A29

D1

A3

A4

A6

D3

A: B134

25

24

28 39 38 6

34

35

40

36

37

B138

* *

B21 E2

E

ELECTRONIC THROTTLE CONTROL

E

: TERMINAL No. OPTIONAL ARRANGEMENT

6

4

5 1 2 3

*

E57

E

B21 B220

1 3 4 2

5 7 8 6

9 11 12 10

A: B134 1 8 9 18 19 28 29

2 10 20 30

B138

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

13 15 16 14

1 2 3 4 5 6 7 8

17 18 20 21 19

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B: B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

E57

C:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07813

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Replace the electronic throttle control.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective.

EN(H4DOTC)(diag)-127

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

Z: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13

B220

M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B17

B7

B220

ECM

E

A28

D: B137

C4

C: B136

A18

B: B135

A19 A1 A2 A29

D1

A3

A4

A6

D3

A: B134

25

24

28 39 38 6

34

35

40

36

37

B138

* *

B21 E2

E

ELECTRONIC THROTTLE CONTROL

E

: TERMINAL No. OPTIONAL ARRANGEMENT

6

4

5 1 2 3

*

E57

E

B21 B220

1 3 4 2

5 7 8 6

9 11 12 10

A: B134 1 8 9 18 19 28 29

2 10 20 30

B138

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

13 15 16 14

1 2 3 4 5 6 7 8

17 18 20 21 19

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B: B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

E57

C:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07813

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 29 — (E57) No. 3:

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 3. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

3

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL CON- more? NECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18:

4

EN(H4DOTC)(diag)-129

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AA:DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Engine does not return to idle. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK TIRE SIZE.

2

CHECK ENGINE COOLANT. Check the following items: • Amount of engine coolant • Engine coolant freeze • Contamination of engine coolant

3

CHECK THERMOSTAT.

Check Yes Is the tire size as specified and Go to step 2. the same size as three other wheels? Is the engine coolant normal? Go to step 3.

Does the thermostat remain opened?

EN(H4DOTC)(diag)-130

No Replace the tire.

Fill or replace the engine coolant.

Replace the ther- Replace the mostat. sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AB:DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

E8

ENGINE COOLANT TEMPERATURE SENSOR

1 2

2 1

E8

A: B134 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

12 6

E2 B21

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

D22 A29

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

A: B134 ECM D: B137

EN-07668

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. Measure the resistance between engine coolant temperature sensor terminals when the engine coolant is cold and after warmed up. Terminals No. 1 — No. 2:

Check Yes Is the resistance of engine cool- Repair the poor ant temperature sensor differ- contact of ECM ent between when engine connector. coolant is cold and after warmed up?

EN(H4DOTC)(diag)-132

No Replace the engine coolant temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AC:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Thermostat remains open. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK ENGINE COOLANT.

Check Is the engine coolant amount normal?

CHECK RADIATOR FAN. 1) Start the engine. 2) Check the radiator fan operation.

Does the radiator fan continuously rotate for 3 minutes or more during idling?

EN(H4DOTC)(diag)-133

Yes Go to step 2.

No Refill the engine coolant. Repair radiator fan Replace the thercircuit. and

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AD:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2

*

7

E3 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

37

D3

C: B136

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07810

1

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H4DOTC)(diag)-134

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 19 — Chassis ground: (B136) No. 18 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of the front oxygen (A/F) sensor connector.

Check Is the resistance 1 MΩ or more?

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

Is there poor contact of front oxygen (A/F) sensor connector?

Repair the poor contact of front oxygen (A/F) sensor connector.

Replace the front oxygen (A/F) sensor.

EN(H4DOTC)(diag)-135

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AE:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2

*

7

E3 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

37

D3

C: B136

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07810

1

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H4DOTC)(diag)-136

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 8 V or more? FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 19 (+) — Chassis ground (–): (B136) No. 18 (+) — Chassis ground (–):

EN(H4DOTC)(diag)-137

Yes Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector.

No Replace the front oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AF:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2 B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

D3

C: B136

37

*

7

E3 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07810

EN(H4DOTC)(diag)-138

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust system? NOTE: Check the following items. • Loose installation of front portion of exhaust pipe onto cylinder heads • Loose connection between front exhaust pipe and front catalytic converter • Damage of exhaust pipe resulting in a hole

EN(H4DOTC)(diag)-139

Yes No Repair the exhaust Replace the front system. oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AG:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2 B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

D3

C: B136

37

: TERMINAL No. OPTIONAL ARRANGEMENT

7

E3

*

35 43 48

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07810

EN(H4DOTC)(diag)-140

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 19 — (E24) No. 3: (B136) No. 18 — (E24) No. 4:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact of ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor.

EN(H4DOTC)(diag)-141

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AH:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B83

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

E25

B503

12 11 B22

E3

B220

2

10

1 2 3 4

1 2 3 4 5 6 7 8

16

9

E

B220

5 7 8 6

1 3 4 2

REAR OXYGEN SENSOR

13 15 16 14

9 11 12 10

17 18 20 21 19

E25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3

1

4

B21

34 42 48

10

9

15

E3 B22

E

B6

C20 C9

* * B30

* * B83

B503

A: B134 ECM C: B136

D1 34

A3

A4

A6

49

37 44 50

38 45 51

39 52

B22

1 5 9 13

2 6 10 14

3 7 11 15

40 46 53

41 47 54

A: B134

4 8 12 16

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B: B135

C: B136

35

40

36

D3

D: B137

37

*

36

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B: B135 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07811

EN(H4DOTC)(diag)-142

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 490 mV or more? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

4

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

5

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Damage (crack, hole etc.) between front oxygen (A/F) sensor and rear oxygen sensor

Is the voltage 0.2 — 0.5 V?

EN(H4DOTC)(diag)-143

No Go to step 2.

Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair or replace Replace the rear faulty parts. oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AI: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B83

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

E25

B503

12 11 B22

E3

B220

2

10

1 2 3 4

1 2 3 4 5 6 7 8

16

9

E

B220

5 7 8 6

1 3 4 2

REAR OXYGEN SENSOR

13 15 16 14

9 11 12 10

17 18 20 21 19

E25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3

1

4

B21

34 42 48

10

9

15

E3 B22

E

B6

C20 C9

* * B30

* * B83

B503

A: B134 ECM C: B136

D1 34

A3

A4

A6

49

37 44 50

38 45 51

39 52

B22

1 5 9 13

2 6 10 14

3 7 11 15

40 46 53

41 47 54

A: B134

4 8 12 16

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B: B135

C: B136

35

40

36

D3

D: B137

37

*

36

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B: B135 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07811

EN(H4DOTC)(diag)-144

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 250 mV or less? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

4

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

5

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Damage (crack, hole etc.) between front oxygen (A/F) sensor and rear oxygen sensor

Is the voltage 0.2 — 0.5 V?

EN(H4DOTC)(diag)-145

No Go to step 2.

Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair or replace Replace the rear faulty parts. oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AJ:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B83

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

E25

B503

12 11 B22

E3

B220

2

10

1 2 3 4

1 2 3 4 5 6 7 8

16

9

E

B220

5 7 8 6

1 3 4 2

REAR OXYGEN SENSOR

13 15 16 14

9 11 12 10

17 18 20 21 19

E25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3

1

4

B21

34 42 48

10

9

15

E3 B22

E

B6

C20 C9

* * B30

* * B83

B503

A: B134 ECM C: B136

D1 34

A3

A4

A6

49

37 44 50

38 45 51

39 52

B22

1 5 9 13

2 6 10 14

3 7 11 15

40 46 53

41 47 54

A: B134

4 8 12 16

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B: B135

C: B136

35

40

36

D3

D: B137

37

*

36

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B: B135 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07811

EN(H4DOTC)(diag)-146

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3:

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. Measure the resistance between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 — Chassis ground: CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor terminals. Terminals No. 3 — No. 4

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Is the resistance 1 MΩ or Go to step 3. Repair the ground more? short circuit of harness between ECM and rear oxygen sensor connector. Is the resistance less than 1 Ω? Replace the rear Even if DTC is oxygen sensor. detected, the cir duce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

EN(H4DOTC)(diag)-147

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AK:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B83

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

E25

B503

12 11 B22

E3

B220

2

10

1 2 3 4

1 2 3 4 5 6 7 8

16

9

E

B220

5 7 8 6

1 3 4 2

REAR OXYGEN SENSOR

13 15 16 14

9 11 12 10

17 18 20 21 19

E25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3

1

4

B21

34 42

10

9

15

E3 B22

E

B6

C20 C9

* * B30

* * B83

B503

A: B134 ECM C: B136

D1 34

A3

A4

A6

37 44 50

38 45 51

39 52

B22

1 5 9 13

2 6 10 14

3 7 11 15

40 46 53

41 47 54

A: B134

4 8 12 16

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B: B135

C: B136

35

40

36

D3

D: B137

37

: TERMINAL No. OPTIONAL ARRANGEMENT

36 49

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B: B135

*

35 43 48

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07811

EN(H4DOTC)(diag)-148

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

Check Yes Is the voltage 490 mV or more? Go to step 6.

No Go to step 2.

Is the voltage 250 mV or less? Go to step 6.

Go to step 3.

Has water entered the connec- Completely tor? remove any water inside. Is the resistance less than 1 Ω? Go to step 5.

Go to step 4.

EN(H4DOTC)(diag)-149

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

5

6

Step CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Check Is the voltage 0.2 — 0.5 V?

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Damage (crack, hole etc.) between front oxygen (A/F) sensor and rear oxygen sensor

Yes Replace the rear oxygen sensor.

Repair or replace faulty parts.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Replace the rear oxygen sensor.

AL:DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2) Refer to DTC P0037 for diagnostic procedure.

AM:DTC P0171 SYSTEM TOO LEAN (BANK 1) Refer to DTC P0172 for diagnostic procedure.

EN(H4DOTC)(diag)-150

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AN:DTC P0172 SYSTEM TOO RICH (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1 2

3

4

Step CHECK EXHAUST SYSTEM.

Check Are there holes or loose bolts on exhaust system? CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 284 — 314 kPa (2.9 — 3.2 kg/cm2, 41 WARNING: — 46 psi)? Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: If fuel pressure does not increase, squeeze the fuel return hose 2 to 3 times, then measure fuel pressure again. CHECK FUEL PRESSURE. Is the measured value 230 — After connecting the pressure regulator vacuum 260 kPa (2.35 — 2.65 kg/cm2, 33 — 38 psi)? hose, measure fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: • If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. • If the measured value at this step is out of specification, check or replace pressure regulator and pressure regulator vacuum hose.

EN(H4DOTC)(diag)-151

Yes No Repair the exhaust Go to step 2. system. Repair the air Go to step 3. intake system. Go to step 4.

Repair the following item. Fuel pressure is too high: • Clogged fuel return line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel supply line

Go to step 5.

Repair the following item. Fuel pressure is too high: • Faulty pressure regulator • Clogged fuel return line or bent hose Fuel pressure is too low: • Faulty pressure regulator • Improper fuel pump discharge • Clogged fuel supply line

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

5

6

7

Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the shift lever in neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the shift lever in neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the temperature 75°C (167°F) or more?

Yes Go to step 6.

No Replace the engine coolant temperature sensor.

Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)?

Go to step 7.

Replace the mass air flow and intake air temperature sensor.

Subtract ambient temperature Repair the poor from intake air temperature. Is contact of ECM the obtained value –10 — 50°C connector. (–18 — 90°F)?

EN(H4DOTC)(diag)-152

Check the mass air flow and intake air temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AO:DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: FUEL TANK

2 3

FUEL TEMPERATURE SENSOR

7 11

R58 R57 R15

3 8

R333 i155

11 5

i3 B38

* *

C23 B30

B83

B : B135

*

ECM

: TERMINAL No. OPTIONAL ARRANGEMENT

C : B136

R57

R58

i155 1 3

4 5 6 8 9 10 11

1 2 2 7

3 4 5 6

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B : B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B83

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

EN-07817

EN(H4DOTC)(diag)-153

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H4DOTC)(diag)-154

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the fuel temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AP:DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: FUEL TANK

2 3

FUEL TEMPERATURE SENSOR

7 11

R58 R57 R15

3 8

R333 i155

11 5

i3 B38

* *

C23 B30

B83

B : B135

*

ECM

: TERMINAL No. OPTIONAL ARRANGEMENT

C : B136

R57

R58

i155 1 3

4 5 6 8 9 10 11

1 2 2 7

3 4 5 6

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B : B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B83

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

EN-07817

EN(H4DOTC)(diag)-155

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the temperature 120°C 1) Start the engine. (248°F) or higher? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or FUEL TEMPERATURE SENSOR CONNEC- more? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and fuel temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 23 — Chassis ground:

EN(H4DOTC)(diag)-156

Yes Go to step 2.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Replace the fuel Repair the ground temperature sen- short circuit of harness between sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AQ:DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: FUEL TANK

2 3

FUEL TEMPERATURE SENSOR

7 11

R58 R57 R15

3 8

R333 i155

11 5

i3 B38

* *

C23 B30

B83

B : B135

*

ECM

: TERMINAL No. OPTIONAL ARRANGEMENT

C : B136

R57

R58

i155 1 3

4 5 6 8 9 10 11

1 2 2 7

3 4 5 6

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B : B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B83

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8

EN-07817

EN(H4DOTC)(diag)-157

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK CURRENT DATA. Is the temperature less than – 1) Start the engine. 40°C (–40°F)? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

2

CHECK FOR POOR CONTACT. Is there poor contact of the Repair any poor contact between the ECM and ECM or fuel temperature senfuel temperature sensor connectors. sor connectors?

3

CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and fuel temperature sensor. 3) Measure the resistance of the harness between the ECM and fuel temperature sensor connector. Connector & terminal (B136) No. 23 — (R58) No. 2: (B135) No. 30 — (R58) No. 3:

4

CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 23 (+) — Chassis ground (–):

Yes Go to step 2.

Repair any poor contact between the ECM and fuel temperature sensor connectors. Is the resistance less than 1 Ω? Go to step 4.

Is the voltage 5 V or more?

EN(H4DOTC)(diag)-158

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel temperature sensor connector • Poor contact of coupling connector Repair the short Replace the fuel circuit to power in temperature senthe harness sor. nector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AR:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13

B220

M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B17

B7

B220

ECM

E

A28

D: B137

C4

C: B136

A18

B: B135

A19 A1 A2 A29

D1

A3

A4

A6

D3

A: B134

25

24

28 39 38 6

34

35

40

36

37

B138

* *

B21 E2

E

ELECTRONIC THROTTLE CONTROL

E

: TERMINAL No. OPTIONAL ARRANGEMENT

6

4

5 1 2 3

*

E57

E

B21 B220

1 3 4 2

5 7 8 6

9 11 12 10

A: B134 1 8 9 18 19 28 29

2 10 20 30

B138

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

13 15 16 14

1 2 3 4 5 6 7 8

17 18 20 21 19

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B: B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

E57

C:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07813

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 28 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 4 — Engine ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Replace the electronic throttle control.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective.

EN(H4DOTC)(diag)-160

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AS:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13

B220

M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B17

B7

B220

ECM

E

A28

D: B137

C4

C: B136

A18

B: B135

A19 A1 A2 A29

D1

A3

A4

A6

D3

A: B134

25

24

28 39 38 6

34

35

40

36

37

B138

* *

B21 E2

E

ELECTRONIC THROTTLE CONTROL

E

: TERMINAL No. OPTIONAL ARRANGEMENT

6

4

5 1 2 3

*

E57

E

B21 B220

1 3 4 2

5 7 8 6

9 11 12 10

A: B134 1 8 9 18 19 28 29

2 10 20 30

B138

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

13 15 16 14

1 2 3 4 5 6 7 8

17 18 20 21 19

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B: B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

E57

C:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07813

EN(H4DOTC)(diag)-161

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 3. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

3

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 4 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL CON- more? NECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 28:

4

EN(H4DOTC)(diag)-162

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AT:DTC P0230 FUEL PUMP PRIMARY CIRCUIT DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY M/B No. 20 14 i3

20 B38

21 FUEL PUMP RELAY

B220

2

i155 R333

8

E FUEL PUMP CONTROL UNIT

R333 4 1

2

1

R15

5

6 7

10

9

R122

R57

i155

10 4

i3

FUEL PUMP R58

C33 B10

6

5

B38

E

ECM

M

B: B135 C: B136

B220

R58

R122

1 2

1 2 3 4 5 6 7 8 9 10

C: B136

3 4 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

5 6

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

R57 1 3

i155

4 5 6 8 9 10 11

B: 2 7

B135

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35

EN-07808

EN(H4DOTC)(diag)-163

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step Check CHECK POWER SUPPLY CIRCUIT TO FUEL Is the voltage 10 V or more? PUMP CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel pump control unit. 3) Turn the ignition switch to ON. 4) Measure the voltage between fuel pump control unit connector and chassis ground. Connector & terminal (R122) No. 8 (+) — Chassis ground (–):

Yes Go to step 2.

CHECK GROUND CIRCUIT OF FUEL PUMP Is the resistance less than 5 Ω? Go to step 3. CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel pump control unit connector and chassis ground. Connector & terminal (R122) No. 5 — Chassis ground: CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 Ω? Go to step 4. CONTROL UNIT AND FUEL PUMP CONNECTOR. 1) Disconnect the connector from fuel pump. 2) Measure the resistance of harness between fuel pump control unit and fuel pump connector. Connector & terminal (R122) No. 9 — (R58) No. 5: (R122) No. 10 — (R58) No. 6:

CHECK HARNESS BETWEEN FUEL PUMP Is the resistance 1 MΩ or Go to step 5. CONTROL UNIT AND FUEL PUMP CONNEC- more? TOR. Measure the resistance between fuel pump control unit connector and chassis ground. Connector & terminal (R122) No. 9 — Chassis ground: (R122) No. 10 — Chassis ground: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 6. FUEL PUMP CONTROL UNIT CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and fuel pump control unit connector. Connector & terminal (B136) No. 33 — (R122) No. 6: (B135) No. 10 — (R122) No. 7:

EN(H4DOTC)(diag)-164

No Repair the power supply circuit. NOTE: In this case, repair the following item: • Open or ground short circuit of harness between fuel pump relay and fuel pump control unit connector • Poor contact of fuel pump relay connector • Poor contact of coupling connector Repair the open circuit in harness between fuel pump control unit and chassis ground.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between fuel pump control unit and fuel pump connector • Poor contact of coupling connector Repair the ground short circuit of harness between fuel pump control unit and fuel pump connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit between ECM and fuel pump control unit connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

7

8

Step CHECK HARNESS BETWEEN ECM AND FUEL PUMP CONTROL UNIT CONNECTOR. Measure the resistance between fuel pump control unit connector and chassis ground. Connector & terminal (R122) No. 6 — Chassis ground: (R122) No. 7 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM and fuel pump control unit connector.

Check Is the resistance 1 MΩ or more?

Yes Go to step 7.

Is there poor contact of ECM or Repair the poor fuel pump control unit connec- contact of ECM or tor? fuel pump control unit connector. CHECK EXPERIENCE OF RUNNING OUT OF Has the vehicle experienced Finish the diagnoFUEL. running out of fuel? sis. NOTE: DTC may be recorded as a result of fuel pump idling while running out of fuel.

EN(H4DOTC)(diag)-165

No Repair the short circuit to ground in harness between ECM and fuel pump control unit connector. Go to step 8.

Replace the fuel pump control unit.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AU:DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” RANGE/PERFORMANCE DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16

B220

4 3 1 3 4 2

2 1

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

B220

B134

E 1 2 8 9 10 18 19 20 28 29 30 B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

ECM

33

E64

1 2

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

48 50

B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

1 2

E64

WASTEGATE CONTROL SOLENOID VALVE

EN-07814

EN(H4DOTC)(diag)-166

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK WASTEGATE ACTUATOR PIPING AND WASTEGATE CONTROL SOLENOID VALVE PIPING.

Are there any damage or disconnection of hose in wastegate actuator piping or wastegate control solenoid valve piping?

EN(H4DOTC)(diag)-167

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Connect the wastegate actuator pipe or wastegate control solenoid valve pipe properly. If defective, replace the hose.

No Go to step 2.

Replace the wastegate control solenoid valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AV:DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16

B220

4 3 1 3 4 2

2 1

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

B220

B134

E 1 2 8 9 10 18 19 20 28 29 30 B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

ECM

33

E64

1 2

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

48 50

B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

1 2

E64

WASTEGATE CONTROL SOLENOID VALVE

EN-07814

EN(H4DOTC)(diag)-168

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 33 (+) — Chassis ground (–): CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is the voltage 10 V or more?

Yes Go to step 2.

No Go to step 3.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

CHECK POWER SUPPLY TO WASTEGATE CONTROL SOLENOID VALVE. Measure the voltage between wastegate control solenoid valve connector and engine ground. Connector & terminal (E64) No. 1 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND WASTEGATE CONTROL SOLENOID VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and wastegate control solenoid valve. 3) Measure the resistance between wastegate control solenoid valve connector and engine ground. Connector & terminal (E64) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND WASTEGATE CONTROL SOLENOID VALVE CONNECTOR. Measure the resistance of harness between ECM and wastegate control solenoid valve connector. Connector & terminal (B134) No. 33 — (E64) No. 2:

Is the voltage 10 V or more?

Go to step 4.

Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary open or short circuit of harness or temporary poor contact of connector may be the cause. Repair the power supply circuit.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair ground short circuit of harness between ECM and wastegate control solenoid valve connector.

Is the resistance less than 1 Ω? Go to step 6.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and wastegate control solenoid valve connector • Poor contact of coupling connector

EN(H4DOTC)(diag)-169

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

Step Check CHECK WASTEGATE CONTROL SOLEIs the resistance 10 — 100 Ω? NOID VALVE. 1) Remove the wastegate control solenoid valve. 2) Measure the resistance between wastegate control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-170

Yes Repair poor contact of wastegate control solenoid valve connector.

No Replace the wastegate control solenoid valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AW:DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

BATTERY

MAIN RELAY M/B No. 16

B220

4 3 1 3 4 2

2 1

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

B220

B134

E 1 2 8 9 10 18 19 20 28 29 30 B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

ECM

33

E64

1 2

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

48 50

B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

1 2

E64

WASTEGATE CONTROL SOLENOID VALVE

EN-07814

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? WASTEGATE CONTROL SOLENOID VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and wastegate control solenoid valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 33 (+) — Chassis ground (–): CHECK WASTEGATE CONTROL SOLEIs the resistance less than 1 Ω? NOID VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between wastegate control solenoid valve terminals. Terminals No. 1 — No. 2:

Yes No Repair short cirGo to step 2. cuit of the harness to power supply between ECM and wastegate control solenoid valve connector.

Replace the waste- Repair the poor gate control sole- contact of ECM noid valve.

AX:DTC P0301 CYLINDER 1 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304.

AY:DTC P0302 CYLINDER 2 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304.

AZ:DTC P0303 CYLINDER 3 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0304.

EN(H4DOTC)(diag)-172

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BA:DTC P0304 CYLINDER 4 MISFIRE DETECTED DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • Immediately at fault recognition (A misfire which could damage catalyst occurs.) • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling • Rough driving CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

E

B220

13 51

12 52

11

ECM

53

54

48

10

B134

B21 E2

FUEL INJECTOR No. 1

E5

E16

E6

E17

1 2

FUEL INJECTOR No. 2

FUEL INJECTOR No. 4

FUEL INJECTOR No. 3

B21

B220

1 3 4 2

5 7 8 6

2

1

E17

2

1

E6

2

1

E16

2

1

E5

9 11 12 10

13 15 16 14

17 18 20 21 19

B134

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

41 47 54

EN-07809

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Measure the resistance between fuel injector connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 2 — Engine ground: #2 (E16) No. 2 — Engine ground: #3 (E6) No. 2 — Engine ground: #4 (E17) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure the resistance of harness between ECM and fuel injector connector on faulty cylinders. Connector & terminal #1 (B134) No. 10 — (E5) No. 2: #2 (B134) No. 11 — (E16) No. 2: #3 (B134) No. 12 — (E6) No. 2: #4 (B134) No. 13 — (E17) No. 2:

Check Is the voltage 10 V or more?

Yes Go to step 6.

No Go to step 2.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the ground short circuit of harness between ECM and fuel injector connector.

Is the resistance less than 1 Ω? Go to step 4.

CHECK FUEL INJECTOR. Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK POWER SUPPLY LINE. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel injector connector of faulty cylinders and engine ground. Connector & terminal #1 (E5) No. 1 (+) — Engine ground (–): #2 (E16) No. 1 (+) — Engine ground (–): #3 (E6) No. 1 (+) — Engine ground (–): #4 (E17) No. 1 (+) — Engine ground (–):

Is the resistance 5 — 20 Ω?

Go to step 5.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel injector connector • Poor contact of coupling connector Replace the faulty fuel injector.

Is the voltage 10 V or more?

Repair the poor contact of all connectors in fuel injector circuit.

EN(H4DOTC)(diag)-174

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between the main relay and fuel injector connector on faulty cylinders • Poor contact of coupling connector • Poor contact of main relay connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

7

8

9

10

11

12

Step CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–): CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK INSTALLATION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR. CHECK CRANK SPROCKET. Remove the timing belt cover. CHECK INSTALLATION CONDITION OF TIMING BELT. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 499987500 CRANKSHAFT SOCKET CHECK FUEL LEVEL.

Check Is the voltage 10 V or more?

Yes No Repair the short Go to step 7. circuit to power in the harness between the ECM and fuel injector.

Is the resistance 5 — 20 Ω?

Replace the faulty Go to step 8. fuel injector.

Is the camshaft position sensor Tighten the cam- Go to step 9. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. Is the crank sprocket rusted or Replace the crank Go to step 10. does it have broken teeth? sprocket. Is the timing belt dislocated Repair the installa- Go to step 11. from its proper position? tion condition of timing belt.

Is the fuel meter indication higher than the “Lower” level?

Go to step 12.

CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator Go to step 14. CATOR LIGHT. light illuminate or blink? 1) Clear the memory using the Subaru Select Monitor or general scan tool.

2) Start the engine, and drive the vehicle 10 minutes or more.

EN(H4DOTC)(diag)-175

Refill the fuel so that fuel meter indication is higher than the “Lower” level. After replenishing fuel, Go to step 12. Go to step 13.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

13

Step CHECK CAUSE OF MISFIRE.

Check Yes Was the cause of misfire identi- Finish diagnostics fied when the engine is runoperation, if the ning? engine has no abnormality.

14

CHECK AIR INTAKE SYSTEM.

Is there any fault in air intake system?

15

CHECK MISFIRE SYMPTOM. 1) Turn the ignition switch to ON. 2) Read the DTC. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK DTC. Is DTC P0301 and P0302 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Is DTC P0303 and P0304 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Is DTC P0301 and P0303 displayed on the Subaru Select Monitor or general scan tool? CHECK DTC. Is DTC P0302 and P0304 displayed on the Subaru Select Monitor or general scan tool?

16

17

18

19

No Repair the poor contact of connector. NOTE: In this case, repair the following item: • Poor contact of ignition coil connector • Poor contact of fuel injector connector on faulty cylinders • Poor contact of ECM connector • Poor contact of coupling connector Go to step 15.

Repair the air intake system. NOTE: Check the following items. • Are there air leaks or air suction caused by loose or dislocated nuts and bolts? • Are there cracks or any disconnection of hoses? Does the Subaru Select Moni- Go to step 20. Go to step 16. tor or general scan tool indicate only one DTC?

EN(H4DOTC)(diag)-176

Go to step 21.

Go to step 17.

Go to step 22.

Go to step 18.

Go to step 23.

Go to step 19.

Go to step 24.

Go to step 25.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

20

Step ONLY ONE CYLINDER.

Check Is there any fault in the cylinder?

21

GROUP OF #1 AND #2 CYLINDERS.

Are there any faults in #1 and #2 cylinders?

22

GROUP OF #3 AND #4 CYLINDERS.

Are there any faults in #3 and #4 cylinders?

EN(H4DOTC)(diag)-177

Yes Repair or replace faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio

No Go to DTC P0171.

Repair or replace Go to DTC P0171. faulty parts.

ratio • If any fault is not found, check the “IGNITION CONTROL SYSTEM” of #1 and #2 cylinders side. Repair or replace Go to DTC P0171. faulty parts.

ratio • If any fault is not found, check the “IGNITION CONTROL SYSTEM” of #3 and #4 cylinders side.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

23

Step GROUP OF #1 AND #3 CYLINDERS.

Check Are there any faults in #1 and #3 cylinders?

24

GROUP OF #2 AND #4 CYLINDERS.

Are there any faults in #2 and #4 cylinders?

25

CYLINDER AT RANDOM.

Is the engine idle rough?

EN(H4DOTC)(diag)-178

Yes Repair or replace faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio • Skipping timing belt teeth Repair or replace faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio • Skipping timing belt teeth Go to DTC P0171.

No Go to DTC P0171.

Go to DTC P0171.

Repair or replace faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BB:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: KNOCK SENSOR

1 2

1

2

E14

E14

A: B134 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

4

6

E2 B21

E

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

D8

D2

A29

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

A: B134 ECM D: B137

EN-07671

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B137) No. 2 — (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor terminals. Terminals No. 1 — No. 2:

Check Is the resistance 600 kΩ or more?

Yes Go to step 2.

No Repair the poor contact of ECM connector.

Is the resistance 600 kΩ or more?

Replace the knock sensor.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and knock sensor connector • Poor contact of knock sensor connector • Poor contact of coupling connector

EN(H4DOTC)(diag)-180

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BC:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: KNOCK SENSOR

1 2

1

2

E14

E14

A: B134 1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

4

6

E2 B21

E

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

D8

D2

A29

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

A: B134 ECM D: B137

EN-07671

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B137) No. 2 — (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor connectors. Terminals No. 1 — No. 2:

Check Yes Is the resistance less than 500 Go to step 2. kΩ?

CHECK INPUT SIGNAL OF ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 2 (+) — Chassis ground (–):

Is the voltage 2 V or more?

Is the resistance less than 500 Replace the knock kΩ? sensor.

EN(H4DOTC)(diag)-182

No Go to step 3.

Repair the ground short circuit of harness between ECM and knock sensor connector. NOTE: The harness between both connectors are shielded. Remove the shield and repair the short circuit of the harness. Even if DTC is Repair the poor detected, the cir- contact of ECM cuit has returned to connector. a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BD:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

CRANKSHAFT POSITION SENSOR

1 2

1

2

E10

E10

B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21

3

14

E2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B21

B137

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

31

17

25

E

ECM

EN-07686

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR. sor installation bolt tightened securely?

Yes Go to step 2.

CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 and 1) Turn the ignition switch to OFF. 4 kΩ? 2) Remove the crankshaft position sensor. 3) Measure the resistance between terminals of crankshaft position sensor. Terminals No. 1 — No. 2: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? CRANKSHAFT POSITION SENSOR CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and crankshaft position sensor connector. Connector & terminal (B137) No. 17 — (E10) No. 1: (B137) No. 25 — (E10) No. 2:

Go to step 3.

EN(H4DOTC)(diag)-184

Repair the poor contact of ECM and crankshaft position sensor connector.

No Tighten the crankshaft position sensor installation bolt securely. Replace the crankshaft position sensor. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and crankshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BE:DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

CRANKSHAFT POSITION SENSOR

1 2

1

2

E10

E10

B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21

3

14

E2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B21

B137

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

31

17

25

E

ECM

EN-07686

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR. sor installation bolt tightened Turn the ignition switch to OFF. securely? CHECK CRANK SPROCKET. Remove the timing belt cover. CHECK INSTALLATION CONDITION OF TIMING BELT. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 499987500 CRANKSHAFT SOCKET

Are crank sprocket teeth cracked or damaged?

Is the timing belt dislocated from its proper position?

EN(H4DOTC)(diag)-186

Yes Go to step 2.

No Tighten the crankshaft position sensor installation bolt securely. Replace the crank Go to step 3. sprocket. Repair the installa- Replace the cranktion condition of shaft position sentiming belt.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BF:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

INTAKE CAMSHAFT POSITION SENSOR LH

B220

INTAKE CAMSHAFT POSITION SENSOR RH

2 3

1

2 3

1

E E35

E36

13 2

5

48

E2

30

16 24

B21

B137

E35

B220

E36 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

ECM

B137

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

EN-07815

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E36) No. 1 (+) — Engine ground (–):

Yes Go to step 2.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and camshaft position sensor connector • Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and camshaft position sensor connector. Connector & terminal (B137) No. 24 — (E36) No. 2: (B137) No. 30 — (E36) No. 3:

3

CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E36) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E36) No. 2 (+) — Engine ground (–): CHECK CONDITION OF CAMSHAFT POSITION SENSOR.

Is the resistance 1 MΩ or more?

Go to step 4.

Is the voltage 5 V or more?

Repair the short Go to step 5. circuit to power in the harness between ECM and camshaft position sensor connector.

CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor.

Is there any abnormality in waveform?

4

5

6

Is the camshaft position sensor Go to step 6. installation bolt tightened securely?

EN(H4DOTC)(diag)-188

Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. camshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BG:DTC P0345 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

INTAKE CAMSHAFT POSITION SENSOR LH

B220

INTAKE CAMSHAFT POSITION SENSOR RH

2 3

1

2 3

1

E E35

E36

13 2

5

48

E2

30

16 24

B21

B137

E35

B220

E36 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

ECM

B137

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

EN-07815

EN(H4DOTC)(diag)-189

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E35) No. 1 (+) — Engine ground (–):

Yes Go to step 2.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and camshaft position sensor connector • Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and camshaft position sensor connector. Connector & terminal (B137) No. 16 — (E35) No. 2: (B137) No. 30 — (E35) No. 3:

3

CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E35) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E35) No. 2 (+) — Engine ground (–): CHECK CONDITION OF CAMSHAFT POSITION SENSOR.

Is the resistance 1 MΩ or more?

Go to step 4.

Is the voltage 5 V or more?

Repair the short Go to step 5. circuit to power in the harness between ECM and camshaft position sensor connector.

CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor.

Is there any abnormality in waveform?

4

5

6

Is the camshaft position sensor Go to step 6. installation bolt tightened securely?

EN(H4DOTC)(diag)-190

Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. camshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BH:DTC P0365 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

EXHAUST CAMSHAFT POSITION SENSOR LH

B220

EXHAUST CAMSHAFT POSITION SENSOR RH

2 3

1

2 3

1

E E65

E62

26 15

5

48

E2

30

29 23

B21

B137

B220

E62 E65 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

ECM

B137

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

EN-07816

EN(H4DOTC)(diag)-191

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E62) No. 1 (+) — Engine ground (–):

Yes Go to step 2.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and camshaft position sensor connector • Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and camshaft position sensor connector. Connector & terminal (B137) No. 23 — (E62) No. 2: (B137) No. 30 — (E62) No. 3:

3

CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E62) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E62) No. 2 (+) — Engine ground (–): CHECK CONDITION OF CAMSHAFT POSITION SENSOR.

Is the resistance 1 MΩ or more?

Go to step 4.

Is the voltage 5 V or more?

Repair the short Go to step 5. circuit to power in the harness between ECM and camshaft position sensor connector.

CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor.

Is there any abnormality in waveform?

4

5

6

Is the camshaft position sensor Go to step 6. installation bolt tightened securely?

EN(H4DOTC)(diag)-192

Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. camshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BI: DTC P0390 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

EXHAUST CAMSHAFT POSITION SENSOR LH

B220

EXHAUST CAMSHAFT POSITION SENSOR RH

2 3

1

2 3

1

E E65

E62

26 15

5

48

E2

30

29 23

B21

B137

B220

E62 E65 1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

ECM

B137

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

EN-07816

EN(H4DOTC)(diag)-193

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E65) No. 1 (+) — Engine ground (–):

Yes Go to step 2.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and camshaft position sensor connector • Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and camshaft position sensor connector. Connector & terminal (B137) No. 29 — (E65) No. 2: (B137) No. 30 — (E65) No. 3:

3

CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E65) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E65) No. 2 (+) — Engine ground (–): CHECK CONDITION OF CAMSHAFT POSITION SENSOR.

Is the resistance 1 MΩ or more?

Go to step 4.

Is the voltage 5 V or more?

Repair the short Go to step 5. circuit to power in the harness between ECM and camshaft position sensor connector.

CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor.

Is there any abnormality in waveform?

4

5

6

Is the camshaft position sensor Go to step 6. installation bolt tightened securely?

EN(H4DOTC)(diag)-194

Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. camshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Idle mixture is out of specifications. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B83

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

E25

B503

12 11 B22

E3

B220

2

10

1 2 3 4

1 2 3 4 5 6 7 8

16

9

E

B220

5 7 8 6

1 3 4 2

REAR OXYGEN SENSOR

13 15 16 14

9 11 12 10

17 18 20 21 19

E25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3

1

4

B21

34 42 48

10

9

15

E3 B22

E

B6

C20 C9

* * B30

* * B83

B503

A: B134 ECM C: B136

D1 34

A3

A4

A6

49

37 44 50

38 45 51

39 52

B22

1 5 9 13

2 6 10 14

3 7 11 15

40 46 53

41 47 54

A: B134

4 8 12 16

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B: B135

C: B136

35

40

36

D3

D: B137

37

*

36

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B: B135 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07811

EN(H4DOTC)(diag)-195

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK EXHAUST SYSTEM. Check for gas leaks or air suction caused by loose or dislocated nuts and bolts, and open hole at exhaust pipes. NOTE: Check the following positions. • Between cylinder head and front exhaust pipe • Between front exhaust pipe and front catalytic converter • Between front catalytic converter and rear catalytic converter • Loose or improperly attached front oxygen (A/F) sensor or rear oxygen sensor CHECK WAVEFORM DATA ON THE SUBARU SELECT MONITOR (WHILE DRIVING). 1) Drive at a constant speed of 80 — 112 km/h (50 — 70 MPH). 2) After 5 minutes have elapsed in the condition of step 1), use the Subaru Select Monitor while still driving to read the waveform data. • At normal condition

Check Is there any fault in exhaust system?

Yes Repair or replace the exhaust system.

Is a normal waveform displayed?

Even if DTC is Go to step 3. detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

1 REAR OXYGEN SENSOR VOLTAGE (V) 0 1.5 A/F SENSOR OUTPUT LAMBDA 1 0.5 10 sec/div

EN-06666

• At abnormal condition (numerous inversion) 1 REAR OXYGEN SENSOR VOLTAGE (V) 0 1.5 A/F SENSOR OUTPUT LAMBDA 1 0.5 10 sec/div

EN-06667

EN(H4DOTC)(diag)-196

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

Step Check CHECK WAVEFORM DATA ON THE SUBA- Is a normal waveform displayed? RU SELECT MONITOR (WHILE IDLING). 1) Run the engine at idle. 2) In the state of step 1), read the waveform data using the Subaru Select Monitor. • At normal condition

Yes Go to step 4.

1

No • The waveform is displayed at abnormal condition 1:Go to step 4. • The waveform is displayed at abnormal condition 2:Go to step 5.

REAR OXYGEN SENSOR VOLTAGE (V)

0 10 sec/div

EN-06668

• At abnormal condition 1 (numerous inversion) 1

REAR OXYGEN SENSOR VOLTAGE (V)

0 10 sec/div

EN-06669

• At abnormal condition 2 (noise input) 1

REAR OXYGEN SENSOR VOLTAGE (V)

0 10 sec/div

4

5

EN-06670

CHECK CATALYTIC CONVERTER.

Is the catalytic converter dam- Replace the cataaged? lytic converter.

CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside.

EN(H4DOTC)(diag)-197

Go to step 5.

Go to step 6.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 7. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

7

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Is the voltage 0.2 — 0.5 V?

8

CHECK REAR OXYGEN SENSOR SHIELD. 1) Turn the ignition switch to OFF. 2) Expose the rear oxygen sensor connector body side harness sensor shield. 3) Measure the resistance between sensor shield and chassis ground.

Is the resistance less than 1 Ω? Replace the rear oxygen sensor.

EN(H4DOTC)(diag)-198

Go to step 8.

No Repair the harness and connector. NOTE: Repair the following locations. • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: Repair the following locations. • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector • Poor contact of ECM connector Repair the open circuit of rear oxygen sensor harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BK:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Fuel odor • There is a hole of more than 1.0 mm (0.04 in) dia. in evaporation system or fuel tank. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

R333

i54 9

10

6

5

i155

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-199

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 1) Turn the ignition switch to OFF. securely? 2) Check the fuel filler cap. NOTE: The DTC is stored in memory if fuel filler cap is or was loose or if the cap chain has caught while tightening. CHECK FUEL FILLER CAP. Is the fuel filler cap genuine?

3

CHECK FUEL FILLER PIPE GASKET.

1

4

5

6

7

Yes Go to step 2.

No Tighten fuel filler cap securely.

Go to step 3.

Replace with a genuine fuel filler cap. Go to step 4.

Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe.

CHECK DRAIN VALVE OPERATION. Does the drain valve operate? Go to step 5. Replace the drain 1) Install the delivery (test) mode fuse. valve. using the Subaru Select Monitor. NOTE: Drain valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”. CHECK OPERATION OF PURGE CONTROL Does the purge control soleGo to step 6. Replace the purge SOLENOID VALVE. noid valve operate? control solenoid Perform operation check for the purge control valve. Purge control solenoid valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK OPERATION OF PRESSURE CON- Does the pressure control sole- Go to step 7. Replace the presTROL SOLENOID VALVE. noid valve operate? sure control solePerform operation check for the pressure connoid valve. NOTE: The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”. CHECK EVAPORATIVE EMISSION CONIs there any hole of more than Repair or replace Go to step 8. TROL SYSTEM LINE. 1.0 mm (0.04 in) dia. on evapo- the evaporation 1) Turn the ignition switch to OFF. ration line? line.

EN(H4DOTC)(diag)-200

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

8

Step CHECK CANISTER.

Check Is the canister damaged or is there a hole of more than 1.0 mm (0.04 in) dia. in it?

9

CHECK FUEL TANK. Remove the fuel tank.

10

CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.

Yes Repair or replace the canister. Is the fuel tank damaged or is Repair or replace there any hole of more than 1.0 the fuel tank. Is there any hole of more than Repair or replace 1.0 mm (0.04 in) dia., crack, the hoses or pipes. clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system?

EN(H4DOTC)(diag)-201

No Go to step 9.

Go to step 10.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BL:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

R333

i54 9

10

6

5

i155

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-202

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 4 (+) — Chassis ground (–): CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is the voltage 10 V or more?

Yes Go to step 2.

No Go to step 3.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

CHECK POWER SUPPLY TO DRAIN VALVE. Measure the voltage between drain valve connector and chassis ground. Connector & terminal (R144) No. 1 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND DRAIN VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and drain valve. 3) Measure the resistance between the drain valve connector and chassis ground. Connector & terminal (R144) No. 2 — Chassis ground: CHECK HARNESS BETWEEN ECM AND DRAIN VALVE CONNECTOR. Measure the resistance of harness between ECM and drain valve connector. Connector & terminal (B135) No. 4 — (R144) No. 2:

Is the voltage 10 V or more?

Go to step 4.

Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary open or short circuit of harness or temporary poor contact of connector may be the cause. Repair the power supply circuit.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the ground short circuit of harness between ECM and drain valve connector.

Is the resistance less than 1 Ω? Go to step 6.

CHECK DRAIN VALVE. Measure the resistance between drain valve terminals. Terminals No. 1 — No. 2:

Is the resistance 10 — 100 Ω? Repair the poor contact of drain valve connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and drain valve connector • Poor contact of coupling connector Replace the drain valve.

EN(H4DOTC)(diag)-203

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BM:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

R333

i54 9

10

6

5

i155

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-204

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? DRAIN VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and drain valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 4 (+) — Chassis ground (–): Is the resistance less than 1 Ω? CHECK DRAIN VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between drain valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-205

Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and drain valve connector.

Replace the drain Repair the poor valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BN:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1

2

3

FUEL TANK PRESSURE SENSOR

R57 9

8

10

R47

R15

10

11

9

R333 i155

*

6

12

2

i3 B38

: TERMINAL No. OPTIONAL ARRANGEMENT

* * B30

C21

B22

B83

B : B135 ECM C : B136

R57

R47

B38

i155 1 2 3 1 3

4 5 6 8 9 10 11

2 7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B83 1 2 3 4 5 6 7 8

B : B135

C : B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07819

1

Step CHECK FUEL FILLER CAP. 1) Turn the ignition switch to OFF. 2) Open the fuel flap.

Check Is the fuel filler cap tightened securely?

EN(H4DOTC)(diag)-206

Yes Go to step 2.

No Tighten fuel filler cap securely.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK PRESSURE/VACUUM LINE. Is there any fault in pressure/ vacuum line? NOTE: Check the following items. • Disconnection, leakage and clogging of the vacuum hoses and pipes between fuel tank pressure sensor and fuel tank • Disconnection, leakage and clogging of air ventilation hoses and pipes between fuel filler pipe and fuel tank

EN(H4DOTC)(diag)-207

Yes Repair or replace the hoses and pipes.

No Replace the fuel tank pressure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BO:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1

2

3

FUEL TANK PRESSURE SENSOR

R57 9

8

10

R47

R15

10

11

9

R333 i155

*

6

12

2

i3 B38

: TERMINAL No. OPTIONAL ARRANGEMENT

* * B30

C21

B22

B83

B : B135 ECM C : B136

R57

R47

B38

i155 1 2 3 1 3

4 5 6 8 9 10 11

2 7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B83 1 2 3 4 5 6 7 8

B : B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07819

EN(H4DOTC)(diag)-208

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the measured value less than Go to step 2. 1) Turn the ignition switch to ON. –7.45 kPa (–55.89 mmHg, – 2) Read the data of fuel tank pressure sensor 2.2003 inHg)? signal using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK FUEL TANK PRESSURE SENSOR Is the voltage 4.5 V or more? POWER SUPPLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between the fuel tank pressure sensor connector and chassis ground. Connector & terminal (R47) No. 3 (+) — Chassis ground (–):

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between the ECM and fuel tank pressure sensor connector. Connector & terminal (B136) No. 21 — (R47) No. 2:

4

CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 21 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact between the ECM and fuel tank pressure sensor connector.

5

Is the resistance 1 MΩ or more?

Go to step 3.

Go to step 5.

Is there poor contact of the Repair the poor ECM or fuel tank pressure sen- contact of the ECM or fuel tank pressor connector? sure sensor connector.

EN(H4DOTC)(diag)-209

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and fuel tank pressure sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and fuel tank pressure sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and fuel tank pressure sensor connector. Replace the fuel tank pressure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BP:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1

2

3

FUEL TANK PRESSURE SENSOR

R57 9

8

10

R47

R15

10

11

9

R333 i155

*

6

12

2

i3 B38

: TERMINAL No. OPTIONAL ARRANGEMENT

* * B30

C21

B22

B83

B : B135 ECM C : B136

R57

R47

B38

i155 1 2 3 1 3

4 5 6 8 9 10 11

2 7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B83 1 2 3 4 5 6 7 8

B : B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07819

EN(H4DOTC)(diag)-210

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Is the measured value 7.98 kPa Go to step 2. 1) Turn the ignition switch to ON. (59.86 mmHg, 2.357 inHg) or 2) Read the data of fuel tank pressure sensor more? signal using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel tank pressure sensor connector and engine ground. Connector & terminal (R47) No. 1 — Engine ground:

Is the measured value 7.98 kPa Repair the short (59.86 mmHg, 2.357 inHg) or circuit to power in more? the harness between ECM and fuel tank pressure sensor connector.

Is the resistance less than 5 Ω? Go to step 4.

CHECK FOR POOR CONTACT. Is there poor contact of fuel Check for poor contact of the fuel tank pressure tank pressure sensor connecsensor connector. tor?

EN(H4DOTC)(diag)-211

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and fuel tank pressure sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair the poor Replace the fuel contact of fuel tank tank pressure senpressure sensor sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BQ:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Fuel odor • There is a hole of more than 0.5 mm (0.020 in) dia. in evaporation system or fuel tank. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

R333

i54 9

10

6

5

i155

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-212

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 1) Turn the ignition switch to OFF. securely? 2) Check the fuel filler cap. NOTE: The DTC is stored in memory if fuel filler cap is or was loose or if the cap chain has caught while tightening. CHECK FUEL FILLER CAP. Is the fuel filler cap genuine?

3

CHECK FUEL FILLER PIPE GASKET.

1

4

5

6

7

Yes Go to step 2.

No Tighten fuel filler cap securely.

Go to step 3.

Replace with a genuine fuel filler cap. Go to step 4.

Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe.

CHECK DRAIN VALVE OPERATION. Does the drain valve operate? Go to step 5. Replace the drain 1) Install the delivery (test) mode fuse. valve. using the Subaru Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK OPERATION OF PURGE CONTROL Does the purge control soleGo to step 6. Replace the purge SOLENOID VALVE. noid valve operate? control solenoid Perform operation check for the purge control valve. Purge control solenoid valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK OPERATION OF PRESSURE CON- Does the pressure control sole- Go to step 7. Replace the presTROL SOLENOID VALVE. noid valve operate? sure control solePerform operation check for the pressure connoid valve. NOTE: The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”. CHECK EVAPORATIVE EMISSION CONIs there any hole of more than Repair or replace Go to step 8. TROL SYSTEM LINE. 0.5 mm (0.020 in) dia. on evap- the evaporation 1) Turn the ignition switch to OFF. oration line? line.

EN(H4DOTC)(diag)-213

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

8

Step CHECK CANISTER.

Check Is the canister damaged or is there a hole of more than 0.5 mm (0.020 in) dia. in it?

9

CHECK FUEL TANK. Remove the fuel tank.

10

CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.

Yes Repair or replace the canister. Is the fuel tank damaged or is Repair or replace there any hole of more than 0.5 the fuel tank. Is there any hole of more than Repair or replace 0.5 mm (0.020 in) dia., crack, the hoses or pipes. clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system?

EN(H4DOTC)(diag)-214

No Go to step 9.

Go to step 10.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BR:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Fuel odor • Fuel filler cap loose or lost CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

R333

i54 9

10

6

5

i155

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-215

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 1) Turn the ignition switch to OFF. securely? 2) Check the fuel filler cap. NOTE: The DTC is stored in memory if fuel filler cap is or was loose or if the cap chain has caught while tightening. CHECK FUEL FILLER CAP. Is the fuel filler cap genuine?

3

CHECK FUEL FILLER PIPE GASKET.

1

4

5

6

7

Yes Go to step 2.

No Tighten fuel filler cap securely.

Go to step 3.

Replace with a genuine fuel filler cap. Go to step 4.

Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe.

CHECK DRAIN VALVE OPERATION. Does the drain valve operate? Go to step 5. Replace the drain 1) Install the delivery (test) mode fuse. valve. using the Subaru Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK OPERATION OF PURGE CONTROL Does the purge control soleGo to step 6. Replace the purge SOLENOID VALVE. noid valve operate? control solenoid Perform operation check for the purge control valve. Purge control solenoid valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK OPERATION OF PRESSURE CON- Does the pressure control sole- Go to step 7. Replace the presTROL SOLENOID VALVE. noid valve operate? sure control solePerform operation check for the pressure connoid valve. NOTE: The pressure control solenoid valve operation can be executed using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”. CHECK EVAPORATIVE EMISSION CONIs there any disconnection, Repair or replace Go to step 8. TROL SYSTEM LINE. damage or clogging on the the evaporation 1) Turn the ignition switch to OFF. evaporation line? line.

EN(H4DOTC)(diag)-216

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step CHECK CANISTER.

Check Is the canister damaged?

9

CHECK FUEL TANK. Remove the fuel tank.

Is the fuel tank damaged?

10

CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.

Are there holes, cracks, clogging, or disconnections, misconnection of hoses or pipes in evaporative emission control system?

8

EN(H4DOTC)(diag)-217

Yes Repair or replace the canister. Repair or replace the fuel tank. Repair or replace the hoses or pipes.

No Go to step 9.

Go to step 10.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BS:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

i54 9

10

6

5

i155 R333

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-218

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 6 (+) — Chassis ground (–): CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is the voltage 10 V or more?

Yes Go to step 2.

No Go to step 3.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

CHECK POWER SUPPLY TO PURGE CONTROL SOLENOID VALVE CONNECTOR. Measure the voltage between purge control solenoid valve connector and engine ground. Connector & terminal (E4) No. 1 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Measure the resistance between the purge control solenoid valve connector and engine ground. Connector & terminal (E4) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE CONNECTOR. Measure the resistance of harness between ECM and purge control solenoid valve connector. Connector & terminal (B137) No. 6 — (E4) No. 2:

Is the voltage 10 V or more?

Go to step 4.

Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary open or short circuit of harness or temporary poor contact of connector may be the cause. Repair the power supply circuit.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the ground short circuit of harness between ECM and purge control solenoid valve connector.

Is the resistance less than 1 Ω? Go to step 6.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and purge control solenoid valve connector • Poor contact of coupling connector Replace the purge control solenoid valve.

CHECK PURGE CONTROL SOLENOID Is the resistance 10 — 100 Ω? VALVE. 1) Remove the purge control solenoid valve. 2) Measure the resistance between purge control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-219

Repair the poor contact of purge control solenoid valve connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BT:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

i54 9

10

6

5

i155 R333

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-220

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? PURGE CONTROL SOLENOID VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 6 (+) — Chassis ground (–): CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 Ω? VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between purge control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-221

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and purge control solenoid valve connector.

Replace the purge Repair the poor control solenoid contact of ECM valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BU:DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the fuel level sensor and fuel sub level sensor.

BV:DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW NOTE: For the diagnostic procedure, refer to DTC P0463.

BW:DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0462 or P0463 displayed on the Subaru Select Monitor?

EN(H4DOTC)(diag)-222

Yes Check the combination meter.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BX:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check Yes CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0464 displayed on the Check the combidisplay? nation meter.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

BY:DTC P0500 VEHICLE SPEED SENSOR “A” DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK DTC OF VDC. Check DTC of VDC.

Check Is DTC of VDC displayed?

EN(H4DOTC)(diag)-223

Yes No Perform the diag- Repair the poor nosis according to contact of ECM DTC.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BZ:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start the engine. • Engine does not start. • Improper idling • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

3

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

CHECK AIR CLEANER ELEMENT. Is there excessive clogging on Replace the air 1) Turn the ignition switch to OFF. air cleaner element? cleaner element. 2) Check the air cleaner element.

CHECK ELECTRONIC THROTTLE CONAre foreign matter found inside Remove foreign TROL. electronic throttle control? matter from elec1) Remove the electronic throttle control. 2) Check the electronic throttle control.

EN(H4DOTC)(diag)-224

No Go to step 2.

Go to step 3.

Perform the diagnosis of DTC P2101.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CA:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Engine keeps running at higher speed than specified idle speed. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

3

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK AIR INTAKE SYSTEM. 1) Start and idle the engine. 2) Check the following items. • Loose installation of intake manifold and throttle body • Cracks of intake manifold gasket and throttle body gasket • Disconnection of vacuum hoses CHECK ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control. 3) Check the electronic throttle control.

Is there any fault in air intake system?

Yes No Check the appro- Go to step 2. priate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Repair air suction Go to step 3. and leaks.

Are foreign matter found inside Remove foreign electronic throttle control? matter from electronic throttle control.

EN(H4DOTC)(diag)-225

Perform the diagnosis of DTC P2101.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CB:DTC P0512 STARTER REQUEST CIRCUIT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B72

IGNITION SWITCH F/B No. 21 6

BATTERY SBF-5 3

E

4

2

2

MAIN SBF

STARTER RELAY

STARTER MOTOR

2

3

1

B493

CLUTCH STROKE SENSOR (CLUTCH START SWITCH)

M

B501

B26

C16

1

B14

ECM B: B135

B72 1 2 3 4 5 6

B493 1 2 3 4

C: B136

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B501 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5

EN-07805

EN(H4DOTC)(diag)-226

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK HARNESS BETWEEN ECM AND STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 16 (+) — Chassis ground (–):

Is the voltage 10 V or more?

EN(H4DOTC)(diag)-227

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Repair the short circuit to power supply in harness between ECM and starter relay connector.

No Go to step 2.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CC:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine does not start. • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY M/B No. 16 4 3

M/B No. 12

1 2

B72

B220

IGNITION SWITCH

BATTERY

F/B No. 12

SBF-5 3

B13 C1 D7

C2 C30

1

MAIN SBF

A : B134

E

B : B135 ECM C : B136

37 36 40 35 34

D3 A6 A4 A3 D1

D : B137

B21 E2

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

A:

B72

B21

39 52

40 46 53

41 47 54

1 2 3 4 5 6

C:

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 D:

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B:

B134

5 6 14 15 16 25 26 27 33 34 35

B220

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

EN(H4DOTC)(diag)-228

EN-07806

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

CD:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR NOTE: For the diagnostic procedure, refer to DTC P0607.

EN(H4DOTC)(diag)-229

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CE:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY M/B No. 16 4 3

M/B No. 12

1 2

B72

B220

IGNITION SWITCH

BATTERY

F/B No. 12

SBF-5 3

C2 C30

B13 C1 D7

1

MAIN SBF

D : B137 ECM A28

A29

A19 A1 A2

D3 A6 A4 A3 D1

C : B136

B135

A18 C4

B:

A : B134

E B138

25

24

6

28 39 38

B21

37 36 40 35 34

* * E2

E

2 10 20 30

6

E57

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3 4 5 6

1 2 3 4 5 6

48

1 8 9 18 19 28 29

4

B72

35 43

36 49

37 44 50

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

38 45 51

39 52

40 46 53

: TERMINAL No. OPTIONAL ARRANGEMENT

E

B21

34 42

A:

ELECTRONIC THROTTLE CONTROL

E57

E

B138 1 2 3 4 5 6 7 8

3

5 1 2

*

B220

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

41 47 54

B:

B135

C:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

D:

B136 5 6 14 15 16 25 26 27 33 34 35

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 28 29 30 31 26 27

EN-07820

EN(H4DOTC)(diag)-230

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK INPUT VOLTAGE OF ECM. Is the voltage 10 — 13 V? Go to step 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 1 (+) — Chassis ground (–): (B137) No. 7 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF ECM. Is the voltage 13 — 15 V? Go to step 3. 1) Start the engine. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 1 (+) — Chassis ground (–): (B137) No. 7 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 19 — (E57) No. 5: (B134) No. 29 — (E57) No. 3: CHECK ECM GROUND HARNESS. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 3 (+) — Chassis ground (–): (B134) No. 4 (+) — Chassis ground (–): (B134) No. 6 (+) — Chassis ground (–): (B137) No. 1 (+) — Chassis ground (–): (B137) No. 3 (+) — Chassis ground (–):

Is the voltage less than 1 V?

Repair the poor contact of ECM connector.

No Repair the open or ground short circuit of power supply circuit.

Repair the open or ground short circuit of power supply circuit.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in ground circuit • Retightening of engine ground terminals • Poor contact of coupling connector

CF:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1) NOTE: For the diagnostic procedure, refer to DTC P2101.

EN(H4DOTC)(diag)-231

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CG:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

ECM

35

4

B136

5 6 14 15 16 25 26 27 33 34 35

B138

*

1 2 3 4 5 6 7 8

B138

*

B25

1 2

2

1

B25 T2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

NEUTRAL POSITION SWITCH

EN-07821

EN(H4DOTC)(diag)-232

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK INPUT SIGNAL OF ECM. Is the voltage 10 V or more? 1) Turn the ignition switch to ON. 2) Place the shift lever in a position other than neutral. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 35 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or NEUTRAL POSITION SWITCH CONNECmore? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and neutral position switch. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 35 — Chassis ground:

EN(H4DOTC)(diag)-233

Yes Repair the poor contact of ECM connector.

No Go to step 2.

Replace the neutral position switch.

Repair the short circuit to ground harness between ECM and neutral position switch connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CH:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

ECM

35

4

B136

5 6 14 15 16 25 26 27 33 34 35

B138

*

1 2 3 4 5 6 7 8

B138

*

B25

1 2

2

1

B25 T2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

NEUTRAL POSITION SWITCH

EN-07821

EN(H4DOTC)(diag)-234

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check CHECK INPUT SIGNAL OF ECM. Is the voltage less than 1 V? 1) Turn the ignition switch to ON. 2) Place the shift lever in neutral. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 35 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? NEUTRAL POSITION SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and neutral position switch. 3) Measure the resistance of harness between ECM and neutral position switch connector. Connector & terminal (B136) No. 35 — (B25) No. 2: (B136) No. 4 — (B25) No. 1: CHECK NEUTRAL POSITION SWITCH. 1) Place the shift lever in neutral. 2) Measure the resistance between neutral position switch terminals. Terminals No. 1 — No. 2:

Yes Repair the poor contact of ECM connector.

No Go to step 2.

Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and neutral position switch connector • Poor contact of coupling connector Replace the neutral position switch.

Is the resistance less than 1 Ω? Repair the poor contact of neutral position switch connector.

EN(H4DOTC)(diag)-235

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CI: DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2

: TERMINAL No. OPTIONAL ARRANGEMENT

7

E3

*

35 43 48

B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

37

D3

C: B136

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07810

1

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H4DOTC)(diag)-236

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 19 — (E24) No. 3: (B136) No. 18 — (E24) No. 4: CHECK FOR POOR CONTACT. Is there poor contact of front Check for poor contact of the front oxygen (A/F) oxygen (A/F) sensor connecsensor connector. tor?

EN(H4DOTC)(diag)-237

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the poor Replace the front contact of front oxygen (A/F) senoxygen (A/F) sen- sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CJ:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2

: TERMINAL No. OPTIONAL ARRANGEMENT

7

E3

*

35 43 48

B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

37

D3

C: B136

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07810

1

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H4DOTC)(diag)-238

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

4

5

Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 19 — Chassis ground: (B136) No. 18 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 19 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 18 (+) — Chassis ground (–):

Check Is the resistance 1 MΩ or more?

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

Is the voltage 4.5 V or more?

Go to step 5.

Go to step 4.

Is the voltage 4.95 V or more? Go to step 5.

Is the voltage 8 V or more? CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 19 (+) — Chassis ground (–): (B136) No. 18 (+) — Chassis ground (–):

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Replace the front oxygen (A/F) sensor. Repair the poor contact of ECM connector.

CK:DTC P1160 RETURN SPRING FAILURE NOTE: For the diagnostic procedure, refer to DTC P2101.

EN(H4DOTC)(diag)-239

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CL:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

R333

i54 9

10

6

5

i155

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-240

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 3 (+) — Chassis ground (–): CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is the voltage 10 V or more?

Yes Go to step 2.

No Go to step 3.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

CHECK POWER SUPPLY TO THE PRESSURE CONTROL SOLENOID VALVE. Measure the voltage between pressure control solenoid valve and chassis ground. Connector & terminal (R68) No. 1 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND PRESSURE CONTROL SOLENOID VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the ECM and pressure control solenoid valve. 3) Measure the resistance between pressure control solenoid valve and chassis ground. Connector & terminal (R68) No. 2 — Chassis ground: CHECK HARNESS BETWEEN ECM AND PRESSURE CONTROL SOLENOID VALVE CONNECTOR. Measure the resistance of harness between ECM and pressure control solenoid valve connector. Connector & terminal (B135) No. 3 — (R68) No. 2:

Is the voltage 10 V or more?

Go to step 4.

Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary open or short circuit of harness or temporary poor contact of connector may be the cause. Repair the power supply circuit.

Is the resistance 1 MΩ or more?

Go to step 5.

Is the resistance less than 1 Ω? Go to step 6.

Repair the ground short circuit of harness between ECM and pressure control solenoid valve connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and pressure control solenoid valve connector • Poor contact of coupling connector CHECK PRESSURE CONTROL SOLENOID Is the resistance 10 — 100 Ω? Repair the poor Replace the presVALVE. contact of pressure sure control soleMeasure the resistance between pressure concontrol solenoid noid valve.

EN(H4DOTC)(diag)-241

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CM:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

i54 9

10

6

5

i155 R333

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-242

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND PRESSURE CONTROL SOLENOID VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the ECM and pressure control solenoid valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 3 (+) — Chassis ground (–): CHECK PRESSURE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between pressure control solenoid valve terminals. Terminals No. 1 — No. 2:

Check Is the voltage 10 V or more?

Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and pressure control solenoid valve connector.

Is the resistance less than 1 Ω? Replace the pres- Repair the poor sure control sole- contact of ECM noid valve.

EN(H4DOTC)(diag)-243

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CN:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper fuel supply CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

R333

i54 9

10

6

5

i155

R99

4

5

R15 R57

R68

E4 E52

1 2

R57

i54

R144

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

1 3

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

i155

4 5 6 8 9 10 11

2 7

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

1

2

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE

E52

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-244

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2 3

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK DRAIN HOSE. Is there clogging in the drain hose? Check the drain hose for clogging. CHECK DRAIN VALVE OPERATION. Does the drain valve operate? 1) Turn the ignition switch to OFF. 2) Install the delivery (test) mode fuse. 3) Turn the ignition switch to ON. 4) Perform operation check for the drain valve using the Subaru Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

EN(H4DOTC)(diag)-245

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Replace the drain hose. Repair the poor contact of ECM connector.

No Go to step 2.

Go to step 3. Replace the drain valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CO:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B72

IGNITION SWITCH F/B No. 21 6

BATTERY SBF-5 3

E

4

2

2

MAIN SBF

STARTER RELAY

STARTER MOTOR

2

3

1

B493

CLUTCH STROKE SENSOR (CLUTCH START SWITCH)

M

B501

B26

C16

1

B14

ECM B: B135

B72 1 2 3 4 5 6

B493 1 2 3 4

C: B136

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

C: B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B501 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5

EN-07805

EN(H4DOTC)(diag)-246

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. Is the resistance less than 1 Ω? Go to step 3. Repair the open circuit of harness between ECM and starter relay connector.

CHECK HARNESS BETWEEN ECM AND STARTER RELAY CONNECTOR. 1) Turn the ignition to OFF. 2) Remove the starter relay. 3) Disconnect the connectors from ECM and starter motor. 4) Measure the resistance of harness between ECM and starter relay connector. Connector & terminal (B136) No. 16 — (B493) No. 3: Is the resistance 1 MΩ or CHECK HARNESS BETWEEN ECM AND more? STARTER RELAY CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 16 — Chassis ground:

EN(H4DOTC)(diag)-247

Repair the poor contact of ECM connector.

Repair the short circuit to ground in harness between ECM and starter relay connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CP:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY M/B No. 16 4 3

M/B No. 12

1 2

IGNITION SWITCH

B72

B220

BATTERY

F/B No. 12

SBF-5 3

B13 C1 D7

C2 C30

1

MAIN SBF

A : B134

E

B : B135 ECM C : B136

37 36 40 35 34

D3 A6 A4 A3 D1

D : B137

B21 E2

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

1

36 49

37 44 50

38 45 51

A:

B72

B21

39 52

40 46 53

41 47 54

1 2 3 4 5 6

C:

1 8 9 18 19 28 29

2 10 20 30

B:

B134

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32 D:

B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

B220

B135

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

1 3 4 2

5 7 8 6

13 15 16 14

17 18 20 21 19

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

Step CHECK INPUT SIGNAL OF ECM. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 2 (+) — Chassis ground (–):

9 11 12 10

Check Is the voltage 10 V or more?

EN(H4DOTC)(diag)-248

EN-07806

Yes Repair the poor contact of ECM connector.

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or MAIN FUSE BOX CONNECTOR. more? 1) Disconnect the connector from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 2 — Chassis ground: CHECK M/B FUSE NO. 12. Is the fuse blown out?

EN(H4DOTC)(diag)-249

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and battery terminal.

Replace the fuse.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and battery • Poor contact of ECM connector • Poor contact of battery terminal

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CQ:DTC P1602 CONTROL MODULE PROGRAMMING ERROR DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine keeps running at higher speed than specified idle speed. • Engine keeps running at a lower speed than the specified idle speed. • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

E

B220

13 51

12 52

11

ECM

53

54

48

10

B134

B21 E2

FUEL INJECTOR No. 1

E5

E16

E6

E17

1 2

FUEL INJECTOR No. 2

FUEL INJECTOR No. 4

FUEL INJECTOR No. 3

B21

B220

1 3 4 2

5 7 8 6

2

1

E17

2

1

E6

2

1

E16

2

1

E5

9 11 12 10

13 15 16 14

17 18 20 21 19

B134

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

36

35 43 48

49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

41 47 54

EN-07809

EN(H4DOTC)(diag)-250

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13

B220

M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B17

B7

B220

ECM

E

A28

C4

D: B137

C: B136

A18

B: B135

A19 A1 A2 A29

D1

A3

A4

A6

D3

A: B134

25

24

28 39 38 6

34

35

40

36

37

B138

* *

B21 E2

E

ELECTRONIC THROTTLE CONTROL

E

: TERMINAL No. OPTIONAL ARRANGEMENT

6

4

5 1 2 3

*

E57

E

B21 B220

1 3 4 2

5 7 8 6

9 11 12 10

A: B134 1 8 9 18 19 28 29

2 10 20 30

B138

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

13 15 16 14

1 2 3 4 5 6 7 8

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

1 2 3 4 5 6

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B: B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

E57

C:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 28 29 26 27

EN-07813

1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

2

CHECK ENGINE OIL.

Is there a proper amount of engine oil?

3

CHECK EXHAUST SYSTEM.

Are there holes or loose bolts on exhaust system?

EN(H4DOTC)(diag)-251

Yes No Check the appro- Go to step 2. priate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Go to step 3. Replace engine oil.

Repair the exhaust Go to step 4. system.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

4

5

6

7

Step CHECK AIR INTAKE SYSTEM.

Check Yes Are there holes, loose bolts or Repair the air disconnection of hose on air intake system. intake system? CHECK FUEL PRESSURE. Is the measured value 284 — Go to step 6. 314 kPa (2.9 — 3.2 kg/cm2, 41 WARNING: Place “NO OPEN FLAMES” signs near the — 46 psi)? working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: If fuel pressure does not increase, squeeze the fuel return hose 2 to 3 times, then measure fuel pressure again. CHECK FUEL PRESSURE. Is the measured value 230 — Go to step 7. After connecting the pressure regulator vacuum 260 kPa (2.35 — 2.65 kg/cm2, 33 — 38 psi)? hose, measure fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: • If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. • If the measured value at this step is out of specification, check or replace pressure regulator and pressure regulator vacuum hose.

CHECK ENGINE COOLANT TEMPERATURE Is the temperature 75°C SENSOR. (167°F) or more? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H4DOTC)(diag)-252

Go to step 8.

No Go to step 5.

Repair the following item. Fuel pressure is too high: • Clogged fuel return line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel supply line

Repair the following item. Fuel pressure is too high: • Faulty pressure regulator • Clogged fuel return line or bent hose Fuel pressure is too low: • Faulty pressure regulator • Improper fuel pump discharge • Clogged fuel supply line Replace the engine coolant temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

8

9

10

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 70°C (158°F). 2) Place the shift lever in neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 70°C (158°F). 2) Place the shift lever in neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–):

Check Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)?

Yes Go to step 9.

Subtract ambient temperature Go to step 10. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

Is the voltage 10 V or more?

EN(H4DOTC)(diag)-253

Go to step 15.

No Replace the mass air flow and intake air temperature sensor.

Check the mass air flow and intake air temperature sensor.

Go to step 11.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

11

12

13

14

15

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or Go to step 12. FUEL INJECTOR CONNECTOR. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Measure the resistance between fuel injector connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 2 — Engine ground: #2 (E16) No. 2 — Engine ground: #3 (E6) No. 2 — Engine ground: #4 (E17) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 13. FUEL INJECTOR CONNECTOR. Measure the resistance of harness between ECM and fuel injector connector on faulty cylinders. Connector & terminal #1 (B134) No. 10 — (E5) No. 2: #2 (B134) No. 11 — (E16) No. 2: #3 (B134) No. 12 — (E6) No. 2: #4 (B134) No. 13 — (E17) No. 2: CHECK FUEL INJECTOR. Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK POWER SUPPLY LINE. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel injector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 (+) — Engine ground (–): #2 (E16) No. 1 (+) — Engine ground (–): #3 (E6) No. 1 (+) — Engine ground (–): #4 (E17) No. 1 (+) — Engine ground (–):

Is the resistance 5 — 20 Ω?

Go to step 14.

Is the voltage 10 V or more?

Repair the poor contact of all connectors in fuel injector circuit.

CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? FUEL INJECTOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–):

EN(H4DOTC)(diag)-254

Repair the short circuit to power in harness between ECM and fuel injector connector.

No Repair the ground short circuit of harness between ECM and fuel injector connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel injector connector • Poor contact of coupling connector Replace the faulty fuel injector. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between the main relay and fuel injector connector on faulty cylinders • Poor contact of coupling connector • Poor contact of main relay connector Go to step 16.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

16

17

18

19

20

21

22

23

Step CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK INSTALLATION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR. CHECK CRANK SPROCKET. Remove the timing belt cover. CHECK INSTALLATION CONDITION OF TIMING BELT. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 499987500 CRANKSHAFT SOCKET CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 13 and No. 14 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 16 — No. 15: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Disconnect the connector from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 — Chassis ground: (B220) No. 15 — Chassis ground:

Check Yes No Is the resistance less than 1 Ω? Replace the faulty Go to step 17. fuel injector.

Is the camshaft position sensor Tighten the cam- Go to step 18. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. Is the crank sprocket rusted or Replace the crank Go to step 19. does it have broken teeth? sprocket. Is the timing belt dislocated Repair the installa- Go to step 20. from its proper position? tion condition of timing belt.

Is the resistance less than 1 Ω? Go to step 21.

Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Go to step 22.

Repair the open or ground short circuit of power supply circuit.

Is the voltage 10 V or more?

Go to step 23. Repair the short circuit to power in the harness between ECM and electronic throttle control relay connector.

Is the resistance 1 MΩ or more?

Go to step 24.

EN(H4DOTC)(diag)-255

Repair the short circuit in harness to ground between ECM and electronic throttle control relay connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

24

25

26

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B135) No. 17 — (B220) No. 14: (B135) No. 7 — (B220) No. 15: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: (B134) No. 28 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground: (E57) No. 4 — Engine ground:

Check Yes Is the resistance less than 1 Ω? Go to step 25.

No Repair the open circuit in harness between ECM and electronic throttle control relay connector.

Is the resistance 1 MΩ or more?

Go to step 26.

Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 27.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector

27

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 28. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

28

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 29. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

EN(H4DOTC)(diag)-256

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

29

30

31

32

33

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): (E57) No. 4 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18: (B134) No. 19 — (B134) No. 28: CHECK SENSOR OUTPUT. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. CHECK SENSOR OUTPUT. Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

Check Is the voltage 5 V or more?

Yes No Repair the short Go to step 30. circuit of harness to power supply between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 31.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Is the voltage 0.81 — 0.87 V?

Go to step 32.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Is the voltage 1.64 — 1.70 V?

Go to step 33.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 34. ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and electronic throttle control connector. Connector & terminal (B134) No. 2 — (E57) No. 2: (B134) No. 1 — (E57) No. 1:

EN(H4DOTC)(diag)-257

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

34

35

36

37

38

39

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 (+) — Engine ground (–): (E57) No. 1 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 — Engine ground: (E57) No. 1 — Engine ground: CHECK ELECTRONIC THROTTLE CONTROL MOTOR HARNESS. Measure the resistance between electronic throttle control connectors. Connector & terminal (E57) No. 2 — (E57) No. 1: CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

Check Is the voltage 5 V or more?

Yes No Repair the short Go to step 35. circuit of harness to power supply between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 36.

Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 37.

Repair the short circuit of harness between ECM and electronic throttle control connector.

Is the resistance less than 5 Ω? Go to step 38.

CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 1 — No. 2: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers.

Is the resistance 50 Ω or less? Go to step 39.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector Replace the electronic throttle control.

Does the valve return to the Repair the poor specified position? Standard contact of ECM value: 3 mm (0.12 in) from fully connector. closed position

EN(H4DOTC)(diag)-258

Replace the electronic throttle control.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CR:DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes No Check the appro- Go to step 2. priate DTC using the “List of Diagnostic Trouble Code (DTC)”.

CHECK TUMBLE GENERATOR VALVE RH. Is there any dirt or clogging with Clean the tumble Replace the tumgenerator valve. ble generator valve 1) Remove the tumble generator valve assem- foreign objects in the tumble bly RH. generator valve? assembly RH. 2) Check the tumble generator valve body.

EN(H4DOTC)(diag)-259

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CS:DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes No Check the appro- Go to step 2. priate DTC using the “List of Diagnostic Trouble Code (DTC)”.

CHECK TUMBLE GENERATOR VALVE LH. Is there any dirt or clogging with Clean the tumble Replace the tumgenerator valve. ble generator valve 1) Remove the tumble generator valve assem- foreign objects in the tumble bly LH. generator valve? assembly LH. 2) Check the tumble generator valve body.

EN(H4DOTC)(diag)-260

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CT:DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes No Check the appro- Go to step 2. priate DTC using the “List of Diagnostic Trouble Code (DTC)”.

CHECK TUMBLE GENERATOR VALVE RH. Is there any dirt or clogging with Clean the tumble Replace the tumgenerator valve. ble generator valve 1) Remove the tumble generator valve assem- foreign objects in the tumble bly RH. generator valve? assembly RH. 2) Check the tumble generator valve body.

EN(H4DOTC)(diag)-261

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CU:DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes No Check the appro- Go to step 2. priate DTC using the “List of Diagnostic Trouble Code (DTC)”.

CHECK TUMBLE GENERATOR VALVE LH. Is there any dirt or clogging with Clean the tumble Replace the tumgenerator valve. ble generator valve 1) Remove the tumble generator valve assem- foreign objects in the tumble bly LH. generator valve? assembly LH. 2) Check the tumble generator valve body.

EN(H4DOTC)(diag)-262

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CV:DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5

TUMBLE GENERATOR VALVE ASSY RH

E55

B21

D11 A29 A19 A26 A25

16 6 28 19 8

E2

ECM A: B134 D: B137

E55

1 2 3 4 5

A: B134

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and tumble generator valve assembly RH. 3) Measure the resistance of harness between ECM and tumble generator valve assembly RH. Connector & terminal (B134) No. 25 — (E55) No. 5: (B134) No. 26 — (E55) No. 4:

CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 25 — Chassis ground: (B134) No. 26 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of tumble generator valve assembly RH connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Is there poor contact of the tum- Repair the poor ble generator valve assembly contact of tumble RH connector? generator valve assembly RH connector.

EN(H4DOTC)(diag)-264

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and tumble generator valve assembly RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and tumble generator valve assembly RH connector. Replace the tumble generator valve assembly RH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CW:DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5

TUMBLE GENERATOR VALVE ASSY RH

E55

B21

D11 A29 A19 A26 A25

16 6 28 19 8

E2

ECM A: B134 D: B137

E55

1 2 3 4 5

A: B134

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 25 (+) — Chassis ground (–): (B134) No. 26 (+) — Chassis ground (–):

EN(H4DOTC)(diag)-266

Yes Repair the short circuit to power in the harness between ECM and tumble generator valve assembly RH.

No Replace the tumble generator valve assembly RH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CX:DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5

TUMBLE GENERATOR VALVE ASSY LH

E51

B21

D10 A29 A19 A24 A23

27 6 28 30 29

E2

ECM A: B134 D: B137

E51

1 2 3 4 5

A: B134

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and tumble generator valve assembly LH. 3) Measure the resistance of harness between ECM and tumble generator valve assembly LH. Connector & terminal (B134) No. 23 — (E51) No. 5: (B134) No. 24 — (E51) No. 4:

CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 23 — Chassis ground: (B134) No. 24 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of tumble generator valve assembly LH connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Is there poor contact of the tum- Repair the poor ble generator valve assembly contact of tumble LH connector? generator valve assembly LH connector.

EN(H4DOTC)(diag)-268

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and tumble generator valve assembly LH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and tumble generator valve assembly LH connector. Replace the tumble generator valve assembly LH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CY:DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5

TUMBLE GENERATOR VALVE ASSY LH

E51

B21

D10 A29 A19 A24 A23

27 6 28 30 29

E2

ECM A: B134 D: B137

E51

1 2 3 4 5

A: B134

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 23 (+) — Chassis ground (–): (B134) No. 24 (+) — Chassis ground (–):

EN(H4DOTC)(diag)-270

Yes Repair the short circuit to power in the harness between ECM and tumble generator valve assembly LH.

No Replace the tumble generator valve assembly LH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CZ:DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5

TUMBLE GENERATOR VALVE ASSY RH

E55

D11 A29 A19 A26 A25

16 6 28 19 8

E2 B21

ECM A: B134 D: B137

E55

1 2 3 4 5

A: B134

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the voltage less than 0.2 V? Go to step 2. 1) Start the engine. 2) Read the data of tumble generator valve position sensor signal (RH) using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK POWER SUPPLY OF TUMBLE GENERATOR VALVE ASSEMBLY RH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from tumble generator valve assembly RH. 3) Turn the ignition switch to ON. 4) Measure the voltage between tumble generator valve assembly RH connector and engine ground. Connector & terminal (E55) No. 3 (+) — Engine ground (–):

3

CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and tumble generator valve assembly RH. Connector & terminal (B137) No. 11 — (E55) No. 1:

4

CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 11 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of tumble generator valve assembly RH connector.

5

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Is the voltage 4.5 V or more? Go to step 3. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and tumble generator valve assembly RH connector • Poor contact of ECM connector • Poor contact of coupling connector Is the resistance less than 1 Ω? Go to step 4. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and tumble generator valve assembly RH connector • Poor contact of coupling connector Is the resistance 1 MΩ or Go to step 5. Repair the short more? circuit to ground in harness between ECM and tumble generator valve assembly RH connector. Replace the tumIs there poor contact of ECM or Repair the poor the tumble generator valve contact of ECM or ble generator valve assembly RH connector? tumble generator assembly RH. valve assembly RH

EN(H4DOTC)(diag)-272

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DA:DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5

TUMBLE GENERATOR VALVE ASSY RH

E55

D11 A29 A19 A26 A25

16 6 28 19 8

E2 B21

ECM A: B134 D: B137

E55

1 2 3 4 5

A: B134

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check CHECK CURRENT DATA. Is the voltage 5 V or more? 1) Start the engine. 2) Read the data of tumble generator valve position sensor signal (RH) using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Yes Go to step 2.

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from tumble generator valve assembly RH. 3) Start the engine. 4) Read the data of tumble generator valve position sensor signal (RH) using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? TUMBLE GENERATOR VALVE ASSEMBLY RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between tumble generator valve assembly RH connector and engine ground. Connector & terminal (E55) No. 2 — Engine ground:

Repair the short circuit to power in harness between ECM and tumble generator valve assembly RH connector.

CHECK FOR POOR CONTACT. Check for poor contact of tumble generator valve assembly RH connector.

Go to step 4.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and tumble generator valve assembly RH connector • Poor contact of ECM connector • Poor contact of coupling connector Is there poor contact of the tum- Repair the poor Replace the tumble generator valve assembly contact of tumble ble generator valve RH connector? generator valve assembly RH. assembly RH con-

EN(H4DOTC)(diag)-274

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DB:DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5

TUMBLE GENERATOR VALVE ASSY LH

E51

D10 A29 A19 A24 A23

27 6 28 30 29

E2 B21

ECM A: B134 D: B137

E51

1 2 3 4 5

A: B134

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the voltage less than 0.2 V? Go to step 2. 1) Start the engine. 2) Read the data of tumble generator valve position sensor signal (LH) using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK POWER SUPPLY OF TUMBLE GENERATOR VALVE ASSEMBLY LH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from tumble generator valve assembly LH. 3) Turn the ignition switch to ON. 4) Measure the voltage between tumble generator valve assembly LH connector and engine ground. Connector & terminal (E51) No. 3 (+) — Engine ground (–):

3

CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and tumble generator valve assembly LH. Connector & terminal (B137) No. 10 — (E51) No. 1:

4

CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 10 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of tumble generator valve assembly LH connector.

5

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Is the voltage 4.5 V or more? Go to step 3. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and tumble generator valve assembly LH connector • Poor contact of ECM connector • Poor contact of coupling connector Is the resistance less than 1 Ω? Go to step 4. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and tumble generator valve assembly LH connector • Poor contact of coupling connector Is the resistance 1 MΩ or Go to step 5. Repair the short more? circuit to ground in harness between ECM and tumble generator valve assembly LH connector. Replace the tumIs there poor contact of ECM or Repair the poor the tumble generator valve contact of ECM or ble generator valve assembly LH connector? tumble generator assembly LH. valve assembly LH

EN(H4DOTC)(diag)-276

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DC:DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5

TUMBLE GENERATOR VALVE ASSY LH

E51

D10 A29 A19 A24 A23

27 6 28 30 29

E2 B21

ECM A: B134 D: B137

E51

1 2 3 4 5

A: B134

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D: B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check CHECK CURRENT DATA. Is the voltage 5 V or more? 1) Start the engine. 2) Read the data of tumble generator valve position sensor signal (LH) using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Yes Go to step 2.

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from tumble generator valve assembly LH. 3) Start the engine. 4) Read the data of tumble generator valve position sensor signal (LH) using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? TUMBLE GENERATOR VALVE ASSEMBLY LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between tumble generator valve assembly LH connector and engine ground. Connector & terminal (E51) No. 2 — Engine ground:

Repair the short circuit to power in harness between ECM and tumble generator valve assembly LH connector.

CHECK FOR POOR CONTACT. Check for poor contact of tumble generator valve assembly LH connector.

Go to step 4.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and tumble generator valve assembly LH connector • Poor contact of ECM connector • Poor contact of coupling connector Is there poor contact of the tum- Repair the poor Replace the tumble generator valve assembly contact of tumble ble generator valve LH connector? generator valve assembly LH. assembly LH con-

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DD:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 1 2 8 9 10 18 19 20 28 29 30

27

34

B134 ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B21

22

21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

E38

1 2

2

1

E38

INTAKE OIL FLOW CONTROL SOLENOID VALVE RH

EN-07680

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve RH. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve RH connector. Connector & terminal (B134) No. 34 — (E38) No. 1: (B134) No. 27 — (E38) No. 2: CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or FLOW CONTROL SOLENOID VALVE RH more? CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 34 — Chassis ground: (B134) No. 27 — Chassis ground: CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-280

Go to step 3.

Repair the poor contact of ECM and oil flow control solenoid valve RH connector RH.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve RH connector. Replace the oil flow control solenoid valve RH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DE:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 1 2 8 9 10 18 19 20 28 29 30

27

34

B134 ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B21

22

21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

E38

1 2

2

1

E38

INTAKE OIL FLOW CONTROL SOLENOID VALVE RH

EN-07680

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve RH. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 34 (+) — Chassis ground (–): (B134) No. 27 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 3. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. Measure the resistance of harness between ECM and oil flow control solenoid valve RH connector. Connector & terminal (B134) No. 34 — (E38) No. 1: (B134) No. 27 — (E38) No. 2:

CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-282

No Repair the short circuit to power supply in harness between ECM and oil flow control solenoid valve RH connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the poor Replace the oil contact of ECM flow control soleand oil flow control noid valve RH. solenoid valve RH

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DF:DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 1 2 8 9 10 18 19 20 28 29 30

15

7

B134 ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B21

17

7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

E63

1 2

2

1

E63

EXHAUST OIL FLOW CONTROL SOLENOID VALVE RH

EN-07681

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve RH. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve RH connector. Connector & terminal (B134) No. 7 — (E63) No. 1: (B134) No. 15 — (E63) No. 2: CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or FLOW CONTROL SOLENOID VALVE RH more? CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 7 — Chassis ground: (B134) No. 15 — Chassis ground: CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-284

Go to step 3.

Repair the poor contact of ECM and oil flow control solenoid valve RH connector RH.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve RH connector. Replace the oil flow control solenoid valve RH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DG:DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 1 2 8 9 10 18 19 20 28 29 30

15

7

B134 ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B21

17

7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

E63

1 2

2

1

E63

EXHAUST OIL FLOW CONTROL SOLENOID VALVE RH

EN-07681

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve RH. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 7 (+) — Chassis ground (–): (B134) No. 15 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 3. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. Measure the resistance of harness between ECM and oil flow control solenoid valve RH connector. Connector & terminal (B134) No. 7 — (E63) No. 1: (B134) No. 15 — (E63) No. 2:

CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-286

No Repair the short circuit to power supply in harness between ECM and oil flow control solenoid valve RH connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the poor Replace the oil contact of ECM flow control soleand oil flow control noid valve RH. solenoid valve RH

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DH:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 1 2 8 9 10 18 19 20 28 29 30

16

17

B134 ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B21

33

32

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

E37

1 2

2

1

E37

INTAKE OIL FLOW CONTROL SOLENOID VALVE LH

EN-07682

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve LH. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve LH connector. Connector & terminal (B134) No. 17 — (E37) No. 1: (B134) No. 16 — (E37) No. 2: CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or FLOW CONTROL SOLENOID VALVE LH more? CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 17 — Chassis ground: (B134) No. 16 — Chassis ground: CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-288

Go to step 3.

Repair the poor contact of ECM and oil flow control solenoid valve LH connector.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve LH connector. Replace the oil flow control solenoid valve LH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DI: DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 1 2 8 9 10 18 19 20 28 29 30

16

17

B134 ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B21

33

32

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

E37

1 2

2

1

E37

INTAKE OIL FLOW CONTROL SOLENOID VALVE LH

EN-07682

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve LH. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 17 (+) — Chassis ground (–): (B134) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 3. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. Measure the resistance of harness between ECM and oil flow control solenoid valve LH connector. Connector & terminal (B134) No. 17 — (E37) No. 1: (B134) No. 16 — (E37) No. 2:

CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-290

No Repair the short circuit to power supply in harness between ECM and oil flow control solenoid valve LH connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the poor Replace the oil contact of ECM flow control soleand oil flow control noid valve LH. solenoid valve LH

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DJ:DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 1 2 8 9 10 18 19 20 28 29 30

14

5

B134 ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B21

43

42

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

E66

1 2

2

1

E66

EXHAUST OIL FLOW CONTROL SOLENOID VALVE LH

EN-07683

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve LH. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve LH connector. Connector & terminal (B134) No. 5 — (E66) No. 1: (B134) No. 14 — (E66) No. 2: CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or FLOW CONTROL SOLENOID VALVE LH more? CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 — Chassis ground: (B134) No. 14 — Chassis ground: CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-292

Go to step 3.

Repair the poor contact of ECM and oil flow control solenoid valve LH connector.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve LH connector. Replace the oil flow control solenoid valve LH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DK:DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B134 1 2 8 9 10 18 19 20 28 29 30

14

5

B134 ECM

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B21

43

42

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 B21 E2

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

E66

1 2

2

1

E66

EXHAUST OIL FLOW CONTROL SOLENOID VALVE LH

EN-07683

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve LH. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 5 (+) — Chassis ground (–): (B134) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 3. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. Measure the resistance of harness between ECM and oil flow control solenoid valve LH connector. Connector & terminal (B134) No. 5 — (E66) No. 1: (B134) No. 14 — (E66) No. 2:

CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H4DOTC)(diag)-294

No Repair the short circuit to power supply in harness between ECM and oil flow control solenoid valve LH connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the poor Replace the oil contact of ECM flow control soleand oil flow control noid valve LH. solenoid valve LH

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DL:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2 B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

D3

C: B136

37

*

7

E3 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

B83

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

E25

B503

12 11 B22

E3

B220

2

10

1 2 3 4

1 2 3 4 5 6 7 8

16

9

E

B220

5 7 8 6

1 3 4 2

REAR OXYGEN SENSOR

13 15 16 14

9 11 12 10

17 18 20 21 19

E25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3

1

4

B21

34 42 48

10

9

15

E3 B22

E

B6

C20 C9

* * B30

* * B83

B503

A: B134 ECM C: B136

D1 34

A3

A4

49

37 44 50

38 45 51

39 52

B22

1 5 9 13

2 6 10 14

3 7 11 15

40 46 53

41 47 54

A: B134

4 8 12 16

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B: B135

C: B136

35

40

36

37

A6

D: B137 D3

*

36

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B: B135 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07811

1

2

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. Has water entered the connec- Completely Go to step 3. tor? remove any water inside.

EN(H4DOTC)(diag)-296

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 19 — (E24) No. 3: (B136) No. 18 — (E24) No. 4:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 19 — Chassis ground: (B136) No. 18 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E24) No. 3 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 4 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 3 (+) — Chassis ground (–): (E24) No. 4 (+) — Chassis ground (–):

Is the resistance 1 MΩ or more?

Go to step 5.

Is the voltage 4.5 V or more?

Go to step 7.

Go to step 6.

Is the voltage 4.95 V or more? Go to step 7.

Go to step 8.

Is the voltage 8 V or more?

Repair the poor contact of ECM connector.

8

CHECK EXHAUST SYSTEM.

9

CHECK AIR INTAKE SYSTEM.

Are there holes or loose bolts on exhaust system? Are there holes, loose bolts or disconnection of hose on air intake system?

5

6

7

EN(H4DOTC)(diag)-297

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Repair the exhaust system. Repair the air intake system.

Go to step 9. Go to step 10.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10

11

12

Step CHECK FUEL PRESSURE. WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: If fuel pressure does not increase, squeeze the fuel return hose 2 to 3 times, then measure fuel pressure again. CHECK FUEL PRESSURE. After connecting the pressure regulator vacuum hose, measure fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: • If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. • If the measured value at this step is out of specification, check or replace pressure regulator and pressure regulator vacuum hose.

Check Yes Is the measured value 284 — Go to step 11. 314 kPa (2.9 — 3.2 kgf/cm2, 41 — 46 psi)?

No Repair the following item. Fuel pressure is too high: • Clogged fuel return line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel supply line

Is the measured value 230 — Go to step 12. 260 kPa (2.35 — 2.65 kgf/cm2, 33 — 38 psi)?

Repair the following item. Fuel pressure is too high: • Faulty pressure regulator • Clogged fuel return line or bent hose Fuel pressure is too low: • Faulty pressure regulator • Improper fuel pump discharge • Clogged fuel supply line Replace the engine coolant temperature sensor.

CHECK ENGINE COOLANT TEMPERATURE Is the temperature 75°C SENSOR. (167°F) or more? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H4DOTC)(diag)-298

Go to step 13.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

13

14

15

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the shift lever in neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the shift lever in neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Depress the clutch pedal. • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/s)?

Yes Go to step 14.

No Replace the mass air flow and intake air temperature sensor.

Subtract ambient temperature Go to step 15. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

Check the mass air flow and intake air temperature sensor.

Is the voltage 490 mV or more? Go to step 16.

Go to step 17.

EN(H4DOTC)(diag)-299

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

16

17

18

19

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 250 mV or less? Go to step 18. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Depress the clutch pedal. • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely remove any water tor? TOR AND COUPLING CONNECTOR. inside. CHECK FRONT OXYGEN (A/F) SENSOR US- Is a voltage of 250 mV or less Replace the front ING REAR OXYGEN SENSOR SIGNAL. maintained for 5 minutes or oxygen (A/F) sen1) Warm up the engine until engine coolant more? sor. using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 20. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

EN(H4DOTC)(diag)-300

No Go to step 17.

Go to step 19.

Go to step 19.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

20

Step CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Check Is the voltage 0.2 — 0.5 V?

EN(H4DOTC)(diag)-301

Yes Replace the rear oxygen sensor.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DM:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B503

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

1 2 3 4 5 6 7 8

12 11

E24

1 2 3 4

8

10 B22

E3

B220

B220

1

9

E 1 3 4 2

FRONT OXYGEN (A/F) SENSOR

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

E24

3 4

2

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

1 2 B22

B22

E 1 5 9 13

C5 C6

C19 C18 C9

* *

2 6 10 14

3 7 11 15

4 8 12 16

B503 A: B134

A: B134 C: B136

1 8 9 18 19 28 29

ECM

D: B137

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

D1 34

A4

A6

A3 35

40

36

D3

C: B136

37

*

7

E3 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

EN-07810

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

B83

BATTERY

A/F, OXYGEN SENSOR RELAY M/B No. 15

E25

B503

12 11 B22

E3

B220

2

10

1 2 3 4

1 2 3 4 5 6 7 8

16

9

E

B220

5 7 8 6

1 3 4 2

REAR OXYGEN SENSOR

13 15 16 14

9 11 12 10

17 18 20 21 19

E25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

3

1

4

B21

34 42 48

10

9

15

E3 B22

E

B6

C20 C9

* * B30

* * B83

B503

A: B134 ECM C: B136

D1 34

A3

A4

49

37 44 50

38 45 51

39 52

B22

1 5 9 13

2 6 10 14

3 7 11 15

40 46 53

41 47 54

A: B134

4 8 12 16

1 8 9 18 19 28 29

2 10 20 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

B: B135

C: B136

35

40

36

37

A6

D: B137 D3

*

36

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

B: B135 : TERMINAL No. OPTIONAL ARRANGEMENT

35 43

B21 E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

E

EN-07811

1

2

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. Has water entered the connec- Completely Go to step 3. tor? remove any water inside.

EN(H4DOTC)(diag)-303

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 19 — (E24) No. 3: (B136) No. 18 — (E24) No. 4:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 19 — Chassis ground: (B136) No. 18 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E24) No. 3 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 4 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 3 (+) — Chassis ground (–): (E24) No. 4 (+) — Chassis ground (–):

Is the resistance 1 MΩ or more?

Go to step 5.

Is the voltage 4.5 V or more?

Go to step 7.

Go to step 6.

Is the voltage 4.95 V or more? Go to step 7.

Go to step 8.

Is the voltage 8 V or more?

Repair the poor contact of ECM connector.

8

CHECK EXHAUST SYSTEM.

9

CHECK AIR INTAKE SYSTEM.

Are there holes or loose bolts on exhaust system? Are there holes, loose bolts or disconnection of hose on air intake system?

5

6

7

EN(H4DOTC)(diag)-304

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Repair the exhaust system. Repair the air intake system.

Go to step 9. Go to step 10.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10

11

12

Step CHECK FUEL PRESSURE. WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: If fuel pressure does not increase, squeeze the fuel return hose 2 to 3 times, then measure fuel pressure again. CHECK FUEL PRESSURE. After connecting the pressure regulator vacuum hose, measure fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. NOTE: • If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. • If the measured value at this step is out of specification, check or replace pressure regulator and pressure regulator vacuum hose.

Check Yes Is the measured value 284 — Go to step 11. 314 kPa (2.9 — 3.2 kgf/cm2, 41 — 46 psi)?

No Repair the following item. Fuel pressure is too high: • Clogged fuel return line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel supply line

Is the measured value 230 — Go to step 12. 260 kPa (2.35 — 2.65 kgf/cm2, 33 — 38 psi)?

Repair the following item. Fuel pressure is too high: • Faulty pressure regulator • Clogged fuel return line or bent hose Fuel pressure is too low: • Faulty pressure regulator • Improper fuel pump discharge • Clogged fuel supply line Replace the engine coolant temperature sensor.

CHECK ENGINE COOLANT TEMPERATURE Is the temperature 75°C SENSOR. (167°F) or more? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H4DOTC)(diag)-305

Go to step 13.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

13

14

15

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the shift lever in neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the shift lever in neutral position. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Depress the clutch pedal. • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/s)?

Yes Go to step 14.

No Replace the mass air flow and intake air temperature sensor.

Subtract ambient temperature Go to step 15. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

Check the mass air flow and intake air temperature sensor.

Is the voltage 490 mV or more? Go to step 16.

Go to step 17.

EN(H4DOTC)(diag)-306

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

16

17

18

19

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 250 mV or less? Go to step 18. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Depress the clutch pedal. • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely remove any water tor? TOR AND COUPLING CONNECTOR. inside. CHECK FRONT OXYGEN (A/F) SENSOR US- Is a voltage of 0.8 V or more Replace the front ING REAR OXYGEN SENSOR SIGNAL. maintained for 5 minutes or oxygen (A/F) sen1) Warm up the engine until engine coolant more? sor. using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 20. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

EN(H4DOTC)(diag)-307

No Go to step 17.

Go to step 19.

Go to step 19.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

20

Step CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Check Is the voltage 0.2 — 0.5 V?

EN(H4DOTC)(diag)-308

Yes Replace the rear oxygen sensor.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DN:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13

B220

M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B17

B7

B220

ECM

E

A28

D: B137

C4

C: B136

A18

B: B135

A19 A1 A2 A29

D1

A3

A4

A6

D3

A: B134

25

24

28 39 38 6

34

35

40

36

37

B138

* *

B21 E2

E

ELECTRONIC THROTTLE CONTROL

E

: TERMINAL No. OPTIONAL ARRANGEMENT

6

4

5 1 2 3

*

E57

E

B21 B220

1 3 4 2

5 7 8 6

9 11 12 10

A: B134 1 8 9 18 19 28 29

2 10 20 30

B138

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

13 15 16 14

1 2 3 4 5 6 7 8

17 18 20 21 19

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B: B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

E57

C:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07813

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 13 and No. 14 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 16 — No. 15: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Disconnect the connector from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 — Chassis ground: (B220) No. 15 — Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B135) No. 17 — (B220) No. 14: (B135) No. 7 — (B220) No. 15: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: (B134) No. 28 — Chassis ground:

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Go to step 3.

Repair the open or ground short circuit of power supply circuit.

Is the voltage 10 V or more?

Repair the short Go to step 4. circuit to power in the harness between ECM and electronic throttle control relay connector.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the short circuit in harness to ground between ECM and electronic throttle control relay connector.

Is the resistance less than 1 Ω? Go to step 6.

Repair the open circuit in harness between ECM and electronic throttle control relay connector.

Go to step 7.

Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

7

Step Check CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 MΩ or 1) Connect the connector to ECM. more? 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground: (E57) No. 4 — Engine ground:

Yes Go to step 8.

8

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 9. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

9

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 10. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

10

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): (E57) No. 4 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL CON- more? NECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18: (B134) No. 19 — (B134) No. 28:

11

EN(H4DOTC)(diag)-311

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Go to step 12.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 11.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

12

13

Step Check CHECK SENSOR OUTPUT. Is the voltage 0.81 — 0.87 V? 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. CHECK SENSOR OUTPUT. Is the voltage 1.64 — 1.70 V? Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

Yes Go to step 13.

No Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Go to step 14.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control • Poor contact of coupling connector Go to step 16.

14

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 15. ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and electronic throttle control connector. Connector & terminal (B134) No. 2 — (E57) No. 2: (B134) No. 1 — (E57) No. 1:

15

CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 (+) — Engine ground (–): (E57) No. 1 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 — Engine ground: (E57) No. 1 — Engine ground: CHECK ELECTRONIC THROTTLE CONTROL MOTOR HARNESS. Measure the resistance between electronic throttle control connectors. Connector & terminal (E57) No. 2 — (E57) No. 1:

16

17

Is the voltage 5 V or more?

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 17.

Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 18.

Repair the short circuit of harness between ECM and electronic throttle control connector.

EN(H4DOTC)(diag)-312

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

18

19

20

Step CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground:

Check Yes Is the resistance less than 5 Ω? Go to step 19.

CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 2 — No. 1: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers.

Is the resistance 50 Ω or less? Go to step 20.

Does the valve return to the Repair the poor specified position? Standard contact of ECM value: 3 mm (0.12 in) from fully connector. closed position

EN(H4DOTC)(diag)-313

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector Replace the electronic throttle control. Replace the electronic throttle control.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DO:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13

B220

M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B17

B7

B220

ECM

E

A28

D: B137

C4

C: B136

A18

B: B135

A19 A1 A2 A29

D1

A3

A4

A6

D3

A: B134

25

24

28 39 38 6

34

35

40

36

37

B138

* *

B21 E2

E

ELECTRONIC THROTTLE CONTROL

E

: TERMINAL No. OPTIONAL ARRANGEMENT

6

4

5 1 2 3

*

E57

E

B21 B220

1 3 4 2

5 7 8 6

9 11 12 10

A: B134 1 8 9 18 19 28 29

2 10 20 30

B138

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

13 15 16 14

1 2 3 4 5 6 7 8

17 18 20 21 19

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B: B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

E57

C:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07813

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 13 and No. 14 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 16 — No. 15: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Disconnect the connector from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 — Chassis ground: (B220) No. 15 — Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B135) No. 17 — (B220) No. 14: (B135) No. 7 — (B220) No. 15:

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Go to step 3.

Repair the open or ground short circuit of power supply circuit.

Is the voltage 10 V or more?

Repair the short Go to step 4. circuit to power in the harness between ECM and electronic throttle control relay connector.

Is the resistance 1 MΩ or more?

Go to step 5.

Is the resistance less than 1 Ω? Repair the poor contact of ECM connector.

EN(H4DOTC)(diag)-315

Repair the short circuit in harness to ground between ECM and electronic throttle control relay connector.

Repair the open circuit in harness between ECM and electronic throttle control relay connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DP:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13

B220

M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B17

B7

B220

ECM

E

A28

D: B137

C4

C: B136

A18

B: B135

A19 A1 A2 A29

D1

A3

A4

A6

D3

A: B134

25

24

28 39 38 6

34

35

40

36

37

B138

* *

B21 E2

E

ELECTRONIC THROTTLE CONTROL

E

: TERMINAL No. OPTIONAL ARRANGEMENT

6

4

5 1 2 3

*

E57

E

B21 B220

1 3 4 2

5 7 8 6

9 11 12 10

A: B134 1 8 9 18 19 28 29

2 10 20 30

B138

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

13 15 16 14

1 2 3 4 5 6 7 8

17 18 20 21 19

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B: B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

E57

C:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 26 27 28 29

EN-07813

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Measure the resistance between electronic throttle control relay terminals. Terminals No. 16 — No. 15: CHECK SHORT CIRCUIT OF ELECTRONIC THROTTLE CONTROL RELAY POWER SUPPLY. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 15 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 17 — Chassis ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Repair the short Go to step 3. circuit to power in the harness between ECM and electronic throttle control relay connector.

Is the resistance 1 MΩ or more?

Repair the poor contact of ECM connector.

Repair the short circuit in harness to ground between ECM and electronic throttle control relay connector.

DQ:DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP PERFORMANCE NOTE: For the diagnostic procedure, refer to DTC P2101.

EN(H4DOTC)(diag)-317

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DR:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B138

B315

B83

1 2 3 4 5 6

1 2 3 4 5 6 7 8

2

3

1

5

6

4

ACCELERATOR PEDAL POSITION SENSOR

B315

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

* *

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B30

B31

B22

B29

B23

A: B134

*

A: B134

: TERMINAL No. OPTIONAL ARRANGEMENT

B: B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

ECM C: B136

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

D1

A3

A4

A6

D: B137 D3

C: B136

34

35

40

B21 36

C4

B21

B83

37

B138

34 42

* *

E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

E

EN-07822

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 21 — Chassis ground: (B135) No. 23 — Chassis ground: (B135) No. 23 — (B136) No. 4: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 — Chassis ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector.

Is the resistance 1 MΩ or more?

Replace the accelerator pedal.

Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective.

EN(H4DOTC)(diag)-319

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DS:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B138

B315

B83

1 2 3 4 5 6

1 2 3 4 5 6 7 8

2

3

1

5

6

4

ACCELERATOR PEDAL POSITION SENSOR

B315

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

* *

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B30

B31

B22

B29

B23

A: B134

*

A: B134

: TERMINAL No. OPTIONAL ARRANGEMENT

B: B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

ECM C: B136

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

D1

A3

A4

A6

D: B137 D3

C: B136

34

35

40

B21 36

C4

B21

B83

37

B138

34 42

* *

E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

E

EN-07822

EN(H4DOTC)(diag)-320

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 Ω? Go to step 2. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance of harness between ECM and accelerator pedal position sensor connector. Connector & terminal (B135) No. 23 — (B315) No. 6: (B135) No. 29 — (B315) No. 5: CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Ω? Go to step 3. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 5 — Chassis ground:

CHECK HARNESS BETWEEN ECM AND AC- Is the voltage 5 V or more? CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 MΩ or CELERATOR PEDAL POSITION SENSOR more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B135) No. 21 — (B135) No. 23:

EN(H4DOTC)(diag)-321

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

Repair the poor contact of accelerator pedal position sensor connector. Replace the accelerator pedal if defective.

No Repair the open circuit of harness between ECM and accelerator pedal position sensor connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DT:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B138

B315

B83

1 2 3 4 5 6

1 2 3 4 5 6 7 8

2

3

1

5

6

4

ACCELERATOR PEDAL POSITION SENSOR

B315

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

* *

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B30

B31

B22

B29

B23

A: B134

*

A: B134

: TERMINAL No. OPTIONAL ARRANGEMENT

B: B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

ECM C: B136

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

D1

A3

A4

A6

D: B137 D3

C: B136

34

35

40

B21 36

C4

B21

B83

37

B138

34 42

* *

E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

E

EN-07822

EN(H4DOTC)(diag)-322

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 22 — Chassis ground: (B135) No. 31 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 3 — Chassis ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector.

Is the resistance 1 MΩ or more?

Replace the accelerator pedal.

Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective.

EN(H4DOTC)(diag)-323

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DU:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B138

B315

B83

1 2 3 4 5 6

1 2 3 4 5 6 7 8

2

3

1

5

6

4

ACCELERATOR PEDAL POSITION SENSOR

B315

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

* *

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B30

B31

B22

B29

B23

A: B134

*

A: B134

: TERMINAL No. OPTIONAL ARRANGEMENT

B: B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

ECM C: B136

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

D1

A3

A4

A6

D: B137 D3

C: B136

34

35

40

B21 36

C4

B21

B83

37

B138

34 42

* *

E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

E

EN-07822

EN(H4DOTC)(diag)-324

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 Ω? Go to step 2. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance of harness between ECM and accelerator pedal position sensor connector. Connector & terminal (B135) No. 31 — (B315) No. 3: (B135) No. 30 — (B315) No. 2:

2

CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 Ω? Go to step 3. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 2 — Chassis ground:

3

CHECK HARNESS BETWEEN ECM AND AC- Is the voltage 5 V or more? CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 3 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 MΩ or CELERATOR PEDAL POSITION SENSOR more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B135) No. 22 — (B135) No. 31:

4

EN(H4DOTC)(diag)-325

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

Repair the poor contact of accelerator pedal position sensor connector. Replace the accelerator pedal if defective.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and accelerator pedal position sensor connector. • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DV:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY ELECTRONIC THROTTLE CONTROL RELAY

M/B No. 13

B220

M/B No. 16

16 13 14 15

3

4 MAIN RELAY

B17

B7

B220

ECM

E

A28

D: B137

C4

C: B136

A18

B: B135

A19 A1 A2 A29

D1

A3

A4

A6

D3

A: B134

25

24

28 39 38 6

34

35

40

36

37

B138

* *

B21 E2

E

ELECTRONIC THROTTLE CONTROL

E

: TERMINAL No. OPTIONAL ARRANGEMENT

6

4

5 1 2 3

*

E57

E

B21 B220

1 3 4 2

5 7 8 6

9 11 12 10

A: B134 1 8 9 18 19 28 29

2 10 20 30

B138

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

13 15 16 14

1 2 3 4 5 6 7 8

17 18 20 21 19

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

B: B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

E57

C:

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32 33 34 35 28 29 30

D:

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 30 31 28 29 26 27

EN-07813

EN(H4DOTC)(diag)-326

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: (B134) No. 28 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground: (E57) No. 4 — Engine ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 6.

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

4

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 5. ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

5

CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): (E57) No. 4 (+) — Engine ground (–):

Is the voltage 5 V or more?

EN(H4DOTC)(diag)-327

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL CON- more? NECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18: (B134) No. 19 — (B134) No. 28:

EN(H4DOTC)(diag)-328

Yes Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

No Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DW:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B138

B315

B83

1 2 3 4 5 6

1 2 3 4 5 6 7 8

2

3

1

5

6

4

ACCELERATOR PEDAL POSITION SENSOR

B315

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

* *

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B30

B31

B22

B29

B23

A: B134

*

A: B134

: TERMINAL No. OPTIONAL ARRANGEMENT

B: B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

ECM C: B136

B: B135 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 33 34 35 28 29 30 31

D1

A3

A4

A6

D: B137 D3

C: B136

34

35

40

B21 36

C4

B21

B83

37

B138

34 42

* *

E2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

D: B137

E

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

E

EN-07822

EN(H4DOTC)(diag)-329

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal Main accelerator pedal position sensor signal (B135) No. 23 (+) — Chassis ground (–): Sub accelerator pedal position sensor signal (B135) No. 31 (+) — Chassis ground (–): CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 (+) — Chassis ground (–): (B315) No. 3 (+) — Chassis ground (–):

Check Yes Is the difference between the Go to step 3. measured value of main accelerator pedal position sensor signal and the measured value of sub accelerator pedal position sensor signal 0 V?

No Go to step 2.

Is the difference between the measured value of main accelerator pedal position sensor signal and the measured value of sub accelerator pedal position sensor signal 0 V?

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and accelerator pedal position sensor connector. • Ground short circuit of harness between ECM and accelerator pedal position sensor connector. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and accelerator pedal position sensor connector. • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector

Replace the accelerator pedal.

CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Ω? Repair the poor CELERATOR PEDAL POSITION SENSOR contact of ECM CONNECTOR. connector. Measure the resistance of harness between the accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 5 — Chassis ground: (B315) No. 2 — Chassis ground:

EN(H4DOTC)(diag)-330

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DX:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check DTC using “List of Diagnostic Trouble Code (DTC)”.

No Replace the ECM.

NOTE: The barometric pressure sensor is built into the ECM.

DY:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H4DOTC)(diag)-331

Yes Check DTC using “List of Diagnostic Trouble Code (DTC)”.

No Replace the ECM.

NOTE: The barometric pressure sensor is built into the ECM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DZ:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H4DOTC)(diag)-332

Yes Check DTC using “List of Diagnostic Trouble Code (DTC)”.

No Replace the ECM.

NOTE: The barometric pressure sensor is built into the ECM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EA:DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

i54 9

10

6

5

i155 R333

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-333

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 15 (+) — Chassis ground (–): CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is the voltage 10 V or more?

Yes Go to step 2.

No Go to step 3.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

CHECK POWER SUPPLY TO PURGE CONTROL SOLENOID VALVE 2. Measure the voltage between purge control solenoid valve 2 connector and engine ground. Connector & terminal (E52) No. 1 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE 2 CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve 2. 3) Measure the resistance between the purge control solenoid valve 2 connector and engine ground. Connector & terminal (E52) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE 2 CONNECTOR. Measure the resistance of harness between ECM and purge control solenoid valve 2 connector. Connector & terminal (B137) No. 15 — (E52) No. 2:

Is the voltage 10 V or more?

Go to step 4.

Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary open or short circuit of harness or temporary poor contact of connector may be the cause. Repair the power supply circuit.

Is the resistance 1 MΩ or more?

Go to step 5.

Is the resistance less than 1 Ω? Go to step 6.

Repair the ground short circuit of harness between ECM and purge control solenoid valve 2 connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and purge control solenoid valve 2 connector • Poor contact of coupling connector CHECK PURGE CONTROL SOLENOID Replace the purge Is the resistance 10 — 100 Ω? Repair the poor VALVE 2. control solenoid contact of the 1) Remove the purge control solenoid valve 2. purge control sole- valve 2. No. 1 — No. 2:

EN(H4DOTC)(diag)-334

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EB:DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY M/B No. 16 4 3 2 1

B220

D15

B4

B21

44

i3

48

B38

15

1

3

E

ECM

B137

D6

D:

11

B135

B3

B:

E2

i54 9

10

6

5

i155 R333

R99

4

5

R15 R57

R68

E52

R144

i54

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13

1 2

R57 1 3

i155

4 5 6 8 9 10 11

2 7

B137

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 30 31 26 27

B:

B135

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 7 8 6

9 11 12 10

2

1

2

PURGE CONTROL SOLENOID VALVE 2

B38

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B220 1 3 4 2

E52

PURGE CONTROL SOLENOID VALVE 1

DRAIN VALVE

1 2 D:

1

2

1

1

2

PRESSURE CONTROL SOLENOID VALVE E4

E4

R144

R68

13 15 16 14

17 18 20 21 19

34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07818

EN(H4DOTC)(diag)-335

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? PURGE CONTROL SOLENOID VALVE 2 CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve 2. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 15 (+) — Chassis ground (–): CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 Ω? VALVE 2. 1) Turn the ignition switch to OFF. 2) Measure the resistance between purge control solenoid valve 2 terminals. Terminals No. 1 — No. 2:

Yes No Repair the short to Go to step 2. power in the harness between ECM and purge control solenoid valve 2 connector.

Replace the purge Repair the poor control solenoid contact of ECM valve 2.

EC:DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION NOTE: For the diagnostic procedure, refer to LAN section.

ED:DTC U0101 CAN (TCU) DATA NOT LOADED NOTE: For the diagnostic procedure, refer to LAN section.

EE:DTC U0122 CAN (VDC) DATA NOT LOADED NOTE: For the diagnostic procedure, refer to LAN section.

EF:DTC U0140 CAN (BCU) DATA NOT LOADED NOTE: For the diagnostic procedure, refer to LAN section.

EG:DTC U0402 CAN (TCU) DATA ABNORMAL NOTE: For the diagnostic procedure, refer to LAN section.

EH:DTC U0416 CAN (VDC) DATA ABNORMAL NOTE: For the diagnostic procedure, refer to LAN section.

EI: DTC U0422 CAN (BCU) DATA ABNORMAL NOTE: For the diagnostic procedure, refer to LAN section.

EN(H4DOTC)(diag)-336

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General Diagnostic Table ENGINE (DIAGNOSTICS)

19.General Diagnostic Table A: INSPECTION 1. ENGINE NOTE: Malfunction of parts other than those listed is also possible. Symptoms

Problem parts 1) Electronic throttle control 2) Manifold absolute pressure sensor 3) Mass air flow and intake air temperature sensor 4) Ignition parts (*1) 1. Engine stalls during idling. 5) Engine coolant temperature sensor (*2) 6) Crankshaft position sensor (*3) 7) Camshaft position sensor (*3) 8) Fuel injection parts (*4) 1) Electronic throttle control 2) Manifold absolute pressure sensor 3) Mass air flow and intake air temperature sensor 4) Engine coolant temperature sensor (*2) 5) Ignition parts (*1) 2. Rough idling 6) Air intake system (*5) 7) Fuel injection parts (*4) 8) Crankshaft position sensor (*3) 9) Camshaft position sensor (*3) 10) Oxygen sensor 11) Fuel pump and fuel pump relay 1) Electronic throttle control 2) Engine coolant temperature sensor 3. Engine does not return to idle. 3) Manifold absolute pressure sensor 4) Mass air flow and intake air temperature sensor 5) Accelerator pedal position sensor 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Electronic throttle control 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay 4. Poor acceleration 6) Engine coolant temperature sensor (*2) 7) Crankshaft position sensor (*3) 8) Camshaft position sensor (*3) 9) Engine torque control signal circuit 10) Ignition parts (*1) 11) Accelerator pedal position sensor 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5. Engine stalls, hesitates, or sputters at accelera5) Camshaft position sensor (*3) tion. 6) Purge control solenoid valve 7) Fuel injection parts (*4) 8) Fuel pump and fuel pump relay 9) Electronic throttle control

EN(H4DOTC)(diag)-337

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General Diagnostic Table ENGINE (DIAGNOSTICS) Symptoms

6. Surging

7. Spark knock

8. After-burning in exhaust system

Problem parts 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5) Camshaft position sensor (*3) 6) Fuel injection parts (*4) 7) Electronic control position sensor 8) Fuel pump and fuel pump relay 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor 4) Knock sensor 5) Fuel injection parts (*4) 6) Fuel pump and fuel pump relay 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay

*1: Check ignition coil and spark plug. *2: Indicate the symptom occurring only in cold temperatures. *3: Ensure the secure installation. *4: Check fuel injector, fuel pressure regulator and fuel filter. *5: Inspect air leak in air intake system.

EN(H4DOTC)(diag)-338

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GENERAL DESCRIPTION

GD(H4DOTC) 1. 2.

Page List of Diagnostic Trouble Code (DTC) ......................................................2 Diagnostic Trouble Code (DTC) Detecting Criteria ..................................10

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION

1. List of Diagnostic Trouble Code (DTC) A: LIST DTC P0011

P0014

Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Exhaust AVCS System 1 (Range/ Performance)

P0016

Crankshaft Position - Camshaft Position Correlation (Bank1)

P0017

Crank and Cam Timing B System Failure (Bank 1)

P0018

Crankshaft Position - Camshaft Position Correlation (Bank2)

P0019

Crank and Cam Timing B System Failure (Bank 2)

P0021

Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 2) Exhaust AVCS System 2 (Range/ Performance)

P0024

P0030 P0031

HO2S Heater Control Circuit (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 1)

P0032

HO2S Heater Control Circuit High (Bank 1 Sensor 1)

P0037

HO2S Heater Control Circuit Low (Bank 1 Sensor 2)

P0038

HO2S Heater Control Circuit High (Bank 1 Sensor 2)

P0068

MAP/MAF - Throttle Position Correlation Mass or Volume Air Flow Circuit Range/Performance

P0101

P0102 P0103 P0107

P0108

Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input

Index













GD(H4DOTC)-2

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0111

Item Intake Air Temperature Sensor 1 Circuit Range/Performance

P0112

Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/ Switch “A” Circuit Low

P0113 P0117 P0118 P0122

P0123

Throttle/Pedal Position Sensor/ Switch “A” Circuit High

P0125

Insufficient Coolant Temperature for Closed Loop Fuel Control

P0126

Insufficient Engine Coolant Temperature for Stable Operation

P0128

Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature)

P0131

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)

P0132

O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)

P0133

O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)

P0134

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)

P0137

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)

P0138

O2 Sensor Circuit High Voltage (Bank 1 Sensor 2)

P0139

O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)

P0140

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)

P0141 P0171

O2 Sensor Heater Circuit (Bank1 Sensor2) System Too Lean (Bank 1)

P0172

System Too Rich (Bank 1)

Index















GD(H4DOTC)-3

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0181

P0182 P0183 P0222

P0223

P0230 P0244

P0245

P0246

P0301 P0302 P0303 P0304 P0327

P0328

P0335 P0336

P0340

P0345 P0365 P0390 P0420

Item Fuel Temperature Sensor “A” Circuit Range/Performance

Index

Fuel Temperature Sensor “A” Cir Fuel Temperature Sensor “A” Cir Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Fuel Pump Primary Circuit

Turbo/Super Charger Wastegate

Turbo/Super Charger Wastegate

Turbo/Super Charger Wastegate

Cylinder 1 Misfire Detected

Cylinder 2 Misfire Detected

Cylinder 3 Misfire Detected

Cylinder 4 Misfire Detected

Knock Sensor 1 Circuit Low (Bank Knock Sensor 1 Circuit High (Bank Crankshaft Position Sensor “A” Cir- Crankshaft Position Sensor “A” Cir- Camshaft Position Sensor “A” Cir- Camshaft Position Sensor “A” Cir- Camshaft Position Sensor “B” Cir- Camshaft Position Sensor “B” Cir- cuit (Bank 2) Catalyst System Efficiency Below

GD(H4DOTC)-4

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0442

Item Evaporative Emission Control System Leak Detected (Small Leak)

P0447

Evaporative Emission Control System Vent Control Circuit Open

P0448

Evaporative Emission Control System Vent Control Circuit Shorted

P0451

Evaporative Emission Control System Pressure Sensor

P0452

Evaporative Emission Control System Pressure Sensor Low Input

P0453

Evaporative Emission Control System Pressure Sensor High Input

P0456

Evaporative Emission Control System Leak Detected (Very Small Leak)

P0457

Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off)

P0458

Evaporative Emission System Purge Control Valve Circuit Low

P0459

Evaporative Emission System Purge Control Valve Circuit High

P0461

Fuel Level Sensor “A” Circuit Range/Performance

P0462

Fuel Level Sensor “A” Circuit Low

P0463

Fuel Level Sensor “A” Circuit High

P0464

Fuel Level Sensor Circuit Intermittent Vehicle Speed Sensor “A”

P0500 P0506

Idle Air Control System RPM Lower Than Expected

P0507

Idle Air Control System RPM Higher Than Expected

P0512

Starter Request Circuit

P0513

Incorrect Immobilizer Key

P0604

Internal Control Module Random Access Memory (RAM) Error

Index













GD(H4DOTC)-5

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0605

P0607

P0638

P0851

P0852

P1152

P1153

P1160 P1400

P1420

P1443

P1518 P1560 P1570 P1571 P1572 P1574 P1576 P1577 P1578 P1602 P2004

Item Internal Control Module Read Only Memory (ROM) Error

Index

Throttle Control System Circuit

Throttle Actuator Control Range/

Neutral Switch Input Circuit Low

Neutral Switch Input Circuit High

O2 Sensor Circuit Range/Perfor O2 Sensor Circuit Range/Perfor Return Spring Failure

Fuel Tank Pressure Control Sole Fuel Tank Pressure Control Sol.

Vent Control Solenoid Valve Func- Starter Switch Circuit Low Input

Back-Up Voltage Circuit Malfunc Antenna

Reference Code Incompatibility

IMM Circuit Failure

Key Communication Failure

EGI Control Module EEPROM

IMM Control Module EEPROM

Meter Failure

Control Module Programming Error Intake Manifold Runner Control

GD(H4DOTC)-6

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P2005

Item Intake Manifold Runner Control Stuck Open (Bank 2)

P2006

Intake Manifold Runner Control Stuck Closed (Bank 1)

P2007

Intake Manifold Runner Control Stuck Closed (Bank 2)

P2008

Intake Manifold Runner Control Circuit / Open (Bank 1)

P2009

Intake Manifold Runner Control Circuit Low (Bank 1)

P2011

Intake Manifold Runner Control Circuit / Open (Bank 2)

P2012

Intake Manifold Runner Control Circuit Low (Bank 2)

P2016

Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 1)

P2017

Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 1)

P2021

Intake Manifold Runner Position Sensor / Switch Circuit Low (Bank 2) Intake Manifold Runner Position Sensor / Switch Circuit High (Bank 2)

P2022

P2088

Intake Camshaft Position Actuator Control Circuit Low (Bank 1)

P2089

Intake Camshaft Position Actuator Control Circuit High (Bank 1)

P2090

Exhaust Camshaft Position Actuator Control Circuit Low (Bank 1)

P2091

Exhaust Camshaft Position Actuator Control Circuit High (Bank 1)

P2092

Intake Camshaft Position Actuator Control Circuit Low (Bank 2)

P2093

Intake Camshaft Position Actuator Control Circuit High (Bank 2)

P2094

Exhaust Camshaft Position Actuator Control Circuit Low (Bank 2)

P2095

Exhaust Camshaft Position Actuator Control Circuit High (Bank 2)

Index













GD(H4DOTC)-7

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P2096

P2097

P2101

P2102

P2103

P2109

P2122

P2123

P2127

P2128

P2135

P2138

Item Post Catalyst Fuel Trim System Too Lean (Bank 1)

Index

Post Catalyst Fuel Trim System

Throttle Actuator Control Motor Cir- Throttle Actuator Control Motor Cir- Throttle Actuator Control Motor Cir- Throttle/Pedal Position Sensor “A” Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

P2227

Atmospheric Pressure Sensor Range/Performance



P2228

Barometric Pressure Circuit Low

P2229

Barometric Pressure Circuit High

P2419

Evaporative Emission System Switching Valve Control Circuit Low

P2420

Evaporative Emission System Switching Valve Control Circuit High

U0073

CAN Failure, Bus ‘OFF’ Detection

U0101

CAN (TCU) Data not Loaded

U0122

CAN (VDC) Data not Loaded



GD(H4DOTC)-8

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC U0140

Item CAN (BCU) Data not Loaded

U0402

CAN (TCU) Data Abnormal

U0416

CAN (VDC) Data Abnormal

U0422

CAN (BCU) Data Abnormal

Index



GD(H4DOTC)-9

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

2. Diagnostic Trouble Code (DTC) Detecting Criteria A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the AVCS system malfunction. Judge NG when the amount of AVCS actual timing advance does not approach to the amount of AVCS target timing advance.

2. COMPONENT DESCRIPTION

(3) (1) (5) (2)

(4)

EN-01852

(1) (2)

AVCS timing controller Vane

(3) (4)

Engine control module (ECM) Oil flow control solenoid valve

(5)

Oil pressure

3. ENABLE CONDITION Secondary Parameters Time of establishing all secondary parameter conditions Battery voltage Engine speed Engine coolant temperature AVCS control Target timing advance change amount (per 64 ms)

Enable Conditions ≥ 3000 ms ≥ 10.9 V ≥ 1500 rpm ≥ 20 °C (68 °F) Operation < 1.07 °CA

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after warming up when the engine speed increases and AVCS operates.

GD(H4DOTC)-10

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD 1) When the conditions during which the differences of AVCS target timing advance amount and AVCS actual timing advance amount is large continues for certain amount of time. 2) When the differences of target timing advance amount and actual timing advance amount is calculated during AVCS control, and the difference per predetermined time is the specified value or larger. • Abnormality Judgment Judge as NG when the following conditions are established within the predetermined time. Judgment Value Malfunction Criteria Σ(Target position – Actual position) or Σ(Target position – Actual position)

Threshold Value > 4500 °CA (Bank 1) > 4500 °CA (Bank 2) < –7000 °CA (Bank 1) < –7000 °CA (Bank 2)

Time Needed for Diagnosis: 30000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established within the predetermined time. Judgment Value Malfunction Criteria Σ(Target position – Actual position)

Threshold Value ≤ 4500 °CA (Bank 1) ≤ 4500 °CA (Bank 2) and ≥ –7000 °CA (Bank 1) ≥ –7000 °CA (Bank 2)

Time Needed for Diagnosis: 30000 ms

GD(H4DOTC)-11

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

B: DTC P0014 EXHAUST AVCS SYSTEM 1 (RANGE/PERFORMANCE) 1. OUTLINE OF DIAGNOSIS Detect the exhaust AVCS system malfunction. Judge NG when the amount of exhaust AVCS actual timing advance does not approach the amount of exhaust AVCS target timing advance.

2. COMPONENT DESCRIPTION

(3) (1) (5) (2)

(4)

EN-01852

(1) (2)

Exhaust AVCS timing controller Vane

(3) (4)

Engine control module (ECM) Oil flow control solenoid valve

(5)

Oil pressure

3. ENABLE CONDITIONS Secondary Parameters Time of establishing all secondary parameter conditions Battery voltage Engine speed Engine coolant temperature Exhaust AVCS control Target timing advance change amount (per 64 ms)

Enable Conditions ≥ 3000 ms ≥ 10.9 V ≥ 1500 rpm ≥ 20 °C (68 °F) Operation < 1.07 °CA

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after warming up when the engine speed increases and exhaust AVCS operates.

GD(H4DOTC)-12

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD 1) When the conditions during which the differences of exhaust AVCS target timing advance amount and exhaust AVCS actual timing advance amount is large continues for certain amount of time. 2) When the differences of target timing advance amount and actual timing advance amount is calculated during exhaust AVCS control, and the difference per predetermined time is the specified value or larger. • Abnormality Judgment Judge as NG when the following conditions are established within the predetermined time. Judgment Value Malfunction Criteria Σ(Target position – Actual position) or Σ(Target position – Actual position)

Threshold Value > 6000 °CA (Bank 1) > 6000 °CA (Bank 2) < –6000 °CA (Bank 1) < –6000 °CA (Bank 2)

Time Needed for Diagnosis: 30000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established within the predetermined time. Judgment Value Malfunction Criteria Σ(Target position – Actual position)

Threshold Value ≤ 6000 °CA (Bank 1) ≤ 6000 °CA (Bank 2) and ≥ –6000 °CA (Bank 1) ≥ –6000 °CA (Bank 2)

Time Needed for Diagnosis: 30000 ms

GD(H4DOTC)-13

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

C: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1) 1. OUTLINE OF DIAGNOSIS Detect the AVCS system malfunction. Judge as NG when standard timing advance amount is far from learning angle.

2. COMPONENT DESCRIPTION

(3) (1) (5) (2)

(4)

EN-01852

(1) (2)

AVCS timing controller Vane

(3) (4)

Engine control module (ECM) Oil flow control solenoid valve

(5)

Hydraulic pressure

3. ENABLE CONDITION Secondary Parameters Battery voltage Engine speed

Engine coolant temperature AVCS control Target timing advance

Enable Conditions ≥ 10.9 V ≥ 600 rpm and < 975 rpm ≥ 72 °C (161.6 °F) Not in operation 0°CA

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting engine and while AVCS is not operating.

GD(H4DOTC)-14

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD Judge as NG when the absolute value of the difference between cam signal input position and learning value is out of specification. • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria |Crankshaft position when camshaft position sensor signal is input – Learning value|

Threshold Value > 9 °CA

Time Needed for Diagnosis: 20000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. NOTE: Initial standard learning value is the value of crank angle initially input at the production plant. And then it will be updated every time normal judgment has been completed. Learning value will not be updated if NG judgment occurs because timing belt or chain derails suddenly in process or because wrong assembly occurs during servicing. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria |Crankshaft position when camshaft position sensor signal is input – Learning value|

Threshold Value ≤ 9 °CA

Time Needed for Diagnosis: Less than 1 second

GD(H4DOTC)-15

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

D: DTC P0017 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the exhaust AVCS system malfunction. Judge as NG when standard timing advance amount is far from learning angle.

2. COMPONENT DESCRIPTION

(3) (1) (5) (2)

(4)

EN-01852

(1) (2)

Exhaust AVCS timing controller Vane

(3) (4)

Engine control module (ECM) Oil flow control solenoid valve

(5)

Oil pressure

3. ENABLE CONDITIONS Secondary Parameters Battery voltage Engine speed

Engine coolant temperature Exhaust AVCS control Target timing advance

Enable Conditions ≥ 10.9 V ≥ 600 rpm and < 975 rpm ≥ 72 °C (161.6 °F) Not in operation 0°CA

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously while the exhaust AVCS is not operating after warming up.

GD(H4DOTC)-16

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD Judge as NG when the absolute value of the difference between cam signal input position and learning value is out of specification. • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria |Crankshaft position when camshaft position sensor signal is input – Learning value|

Threshold Value > 9 °CA

Time Needed for Diagnosis: 20000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. NOTE: Initial standard learning value is the value of crank angle initially input at the production plant. And then it will be updated every time normal judgment has been completed. Learning value will not be updated if NG judgment occurs because timing belt or chain derails suddenly in process or because wrong assembly occurs during servicing. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria |Crankshaft position when camshaft position sensor signal is input – Learning value|

Threshold Value ≤ 9 °CA

Time Needed for Diagnosis: Less than 1 second

GD(H4DOTC)-17

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

E: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0016.

F: DTC P0019 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0017.

G: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0011.

H: DTC P0024 EXHAUST AVCS SYSTEM 2 (RANGE/PERFORMANCE) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0014.

GD(H4DOTC)-18

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

I:

DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

1. OUTLINE OF DIAGNOSIS Detect functional errors of the front oxygen (A/F) sensor heater. Judge as NG when it is determined that the front oxygen (A/F) sensor impedance is large when looking at engine status such as deceleration fuel cut.

2. COMPONENT DESCRIPTION

(1)

(2)

(3)

(4)

(5)

EN-07655

(1) (2)

Element cover (outer) Element cover (inner)

(3) (4)

Sensor element Ceramic heater

(5)

Sensor housing

3. ENABLE CONDITION Secondary Parameters Condition established time Battery voltage Heater current Control duty ≥ 35 % After fuel cut

Enable Conditions ≥ 42000 ms ≥ 10.9 V Permitted Experienced ≥ 20000 ms

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after 42000 ms seconds or more have passed since the engine started.

GD(H4DOTC)-19

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Front oxygen (A/F) sensor impedance

Threshold Value > 50 Ω

Time Needed for Diagnosis: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Front oxygen (A/F) sensor impedance

Threshold Value ≤ 50 Ω

Time Needed for Diagnosis: 10000 ms

GD(H4DOTC)-20

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

J: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect front oxygen (A/F) sensor heater open or short circuit. The front oxygen (A/F) sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains Low.

2. COMPONENT DESCRIPTION

(A) OFF (B)

(D)

ON 0V

(C)

EN-01792

(A)

Battery voltage

(D)

Low error

(B)

Front oxygen (A/F) sensor heater output voltage

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(C)

128 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Front oxygen (A/F) sensor heater control duty

Threshold Value Low < 87.5 %

Time Needed for Diagnosis:4 ms × 250 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

K: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect front oxygen (A/F) sensor heater open or short circuit. The front oxygen (A/F) sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains High.

2. COMPONENT DESCRIPTION

(A) (D)

OFF

(B)

ON 0V

(C)

EN-01793

(A)

Battery voltage

(D)

High error

(B)

Front oxygen (A/F) sensor heater output voltage

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(C)

128 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Front oxygen (A/F) sensor heater control duty

Threshold Value High ≥ 12.5 %

Time Needed for Diagnosis:4 ms × 500 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

L: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect the rear oxygen sensor heater open or short circuit. The rear oxygen sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains Low.

2. COMPONENT DESCRIPTION

(A) OFF (B)

ON

(D)

0V

(C)

EN-01792

(A)

Battery voltage

(D)

Low error

(B)

Output voltage of the rear oxygen sensor heater

(C)

256 ms (cycle)

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine Engine speed

Enable Conditions ≥ 10.9 V ≥ 1 second < 8000 rpm

4. GENERAL DRIVING CYCLE After starting the engine, perform the diagnosis continuously when engine is low speed.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Rear oxygen sensor heater control duty

Threshold Value Low < 75 %

Time Needed for Diagnosis:8 ms × 1250 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

M: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect the rear oxygen sensor heater open or short circuit. The rear oxygen sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains High.

2. COMPONENT DESCRIPTION

(A) (D)

OFF

(B)

ON 0V

(C)

EN-01793

(A)

Battery voltage

(D)

High error

(B)

Output voltage of the rear oxygen sensor heater

(C)

256 ms (cycle)

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine Engine speed

Enable Conditions ≥ 10.9 V ≥ 1 second < 8000 rpm

4. GENERAL DRIVING CYCLE After starting the engine, perform the diagnosis continuously when engine is low speed.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Rear oxygen sensor heater control duty

Threshold Value High ≥ 25 %

Time Needed for Diagnosis:8 ms × 1250 time (s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

N: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION 1. OUTLINE OF DIAGNOSIS Detect problems in the intake manifold pressure sensor output properties. Judge as NG when the intake air pressure AD value is Low whereas it seemed to be High from the viewpoint of engine condition, or when it is High whereas it seemed to be Low from the engine condition.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(B)

(3)

EN-01765

(A)

Output voltage

(B)

Absolute pressure

(1)

Connector

(2)

Terminals

3. ENABLE CONDITION Secondary Parameters Engine coolant temperature

Enable Conditions ≥ 72 °C (161.6 °F)

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after idling.

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(3)

O-ring

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when Low side or High side becomes NG. If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load

Threshold Value < 3000 rpm ≥ 16 ° 0.96 g/rev (0.03 oz/rev) 600 rpm — 900 rpm < 5.13 ° ≥ 2.36 V < 0.48 g/rev (0.02 oz/rev)

Time Needed for Diagnosis: Low side: 3000 ms High side: 3000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG when both Low side and High side become OK. If the duration of time while the following conditions are met is longer than the time indicated, judge as OK. Judgment Value Malfunction Criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load

Threshold Value < 3000 rpm ≥ 16 ° ≥1V > 0.96 g/rev (0.03 oz/rev) 600 rpm — 900 rpm < 5.13 ° < 2.36 V < 0.48 g/rev (0.02 oz/rev)

Time Needed for Diagnosis: Low side: Less than 1 s High side: Less than 1 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

O: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect the malfunction of air flow sensor output properties. Judge as a low side NG when the air flow voltage indicates a small value regardless of running in a state where the air flow voltage increases. Judge as a high side NG when the air flow voltage indicates a large value regardless of running in a state where the air flow voltage decreases. Judge air flow sensor property NG when the Low side or High side becomes NG.

2. COMPONENT DESCRIPTION

(1)

(3) (2)

(A)

(4)

EN-01766

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Voltage (V)

3. ENABLE CONDITION Secondary Parameters Engine coolant temperature

Enable Conditions ≥ 72 °C (161.6 °F)

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after idling.

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(4)

Amount of intake air (kg (lb)/s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when Low side or High side becomes NG. If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Low Output voltage Engine speed Throttle opening angle Intake manifold pressure High (1) Output voltage Engine speed Throttle opening angle Intake manifold pressure High (2) Output voltage Engine speed Throttle opening angle Intake manifold pressure Fuel system diagnosis

Threshold Value < 1.5 V ≥ 2300 rpm ≥ 16 ° ≥ 66.7 kPa (500 mmHg, 19.7 inHg) ≥ 1.95 V 600 rpm — 900 rpm < 5.13 ° ≥ 50 kPa (375 mmHg, 14.8 inHg) ≥ 1.65 V 600 rpm — 900 rpm < 5.13 ° ≥ 50 kPa (375 mmHg, 14.8 inHg) Rich side malfunction

Time Needed for Diagnosis: Low: 3000 ms High: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG when both Low side and High side become OK. Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Low Output voltage Engine speed Throttle opening angle Intake manifold pressure High Output voltage Engine speed Throttle opening angle Intake manifold pressure Fuel system diagnosis

Threshold Value ≥ 1.5 V ≥ 2300 rpm ≥ 16 ° ≥ 66.7 kPa (500 mmHg, 19.7 inHg) < 1.95 V 600 rpm — 900 rpm < 5.13 ° < 50 kPa (375 mmHg, 14.8 inHg) Rich side normal

Time Needed for Diagnosis: Low: Less than 1 s High: Less than 1 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

P: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect open or short circuits of the air flow sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3) (2)

(A)

(4)

EN-01766

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Voltage (V)

(4)

Amount of intake air (kg (lb)/s)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≤ 0.22 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value > 0.22 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Q: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect open or short circuits of the air flow sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3) (2)

(A)

(4)

EN-01766

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Voltage (V)

(4)

Amount of intake air (kg (lb)/s)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.98 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.98 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

R: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of intake manifold pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(B)

(3)

EN-01765

(A)

Output voltage

(B)

Absolute pressure

(1)

Connector

(2)

Terminals

(3)

O-ring

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≤ 0.573 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value > 0.573 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

S: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of intake manifold pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(B)

(3)

EN-01765

(A)

Output voltage

(B)

Absolute pressure

(1)

Connector

(2)

Terminals

(3)

O-ring

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.596 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.596 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

T: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect the malfunction of intake air temperature sensor output property. Judge as NG when the intake air temperature is not varied whereas it seemed to be varied from the viewpoint of engine condition.

2. COMPONENT DESCRIPTION

(1)

(3)

(2) (A) (4)

EN-01767

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Resistance value (Ω)

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(4)

Intake air temperature °C (°F)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Engine coolant temperature at engine starting Battery voltage Continuous time when the vehicle speed is less than 140 km/h (87 MPH) Engine coolant temperature Intake air amount sum value Number of experiences under conditions below • Continuous time when vehicle speed is less than 4 km/h (2.5 MPH) • Continuous time when vehicle speed is 40 km/h (24.9 MPH) or more and Establishing time of 1, 2 1. Intake air amount 2. Vehicle speed

Enable Conditions < 35 °C (95 °F) ≥ 10.9 V ≥ 610 s ≥ 72 °C (161.6 °F) ≥ Value of Map 1 ≥ 3 time(s) ≥ Value from Map 2 ≥ 15 s

≥ 15 s ≥ 15 g/s (0.53 oz/s) ≥ 4 km/h (2.5 MPH)

Map 1 Engine coolant temperature °C (°F) Intake air amount sum value (g (oz)/s)

–20 (–4) 76000 (2680.52)

–10 (14) 8880 (313.2)

0 (32) 8153 (287.56)

10 (50) 7427 (261.95)

–20 (–4)

–10 (14)

5 (41)

20 (68)

250

40

32

24

20 (68) 6009 (211.94)

Map 2 Engine coolant temperature °C (°F) Continuous time (s) when vehicle speed is less than 4 km/h (2.5 MPH)

4. GENERAL DRIVING CYCLE Perform the diagnosis when the vehicle speed condition is met after warming up from a cold condition.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Output voltage difference between Max. and Min.

Threshold Value < 0.02 V(Equivalent to approximately 0.5°C (0.9°F) near 25°C)

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Output voltage difference between Max. and Min.

Threshold Value ≥ 0.02 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

U: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the intake air temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3)

(2) (A) (4)

EN-01767

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Resistance value (Ω)

(4)

Intake air temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.231 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.231 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

V: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the intake air temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3)

(2) (A) (4)

EN-01767

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Resistance value (Ω)

(4)

Intake air temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.716 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.716 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

W: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the engine coolant temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.275 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.275 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

X: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the engine coolant temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.716 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.716 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Y: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value ≤ 0.217 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value > 0.217 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Z: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value ≥ 4.858 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value < 4.858 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AA:DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL 1. OUTLINE OF DIAGNOSIS Detect the malfunction of engine coolant temperature output property. Judge as NG when the engine coolant temperature does not rise in driving conditions where it should.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters Engine speed Battery voltage

Enable Conditions ≥ Value from Map ≥ 10.9 V

Map Engine coolant temperature °C (°F) Engine speed rpm

–40 (–40)

–30 (–22)

–20 (–4)

–10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

500

500

500

500

500

500

500

500

Engine coolant temperature °C (°F) Engine speed rpm

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100 (212)

110 (230)

500

500

500

500

500

500

500

500

4. GENERAL DRIVING CYCLE Perform the diagnosis only once after engine start.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG if the criteria below are met. Judgment Value Malfunction Criteria Engine coolant temperature Timer for diagnosis after engine start

Threshold Value < 20 °C (68 °F) ≥ Judgment value of timer after engine start

Timer for diagnosis after engine start a. Timer stop at fuel cut b. During the driving conditions except a) above, timer counts up as follows. 64 ms + TWCNT ms (at 64 ms) TWCNT is defined as follows, TWCNT = 0 at idle switch ON, TWCNT show on the following table at idle switch OFF.

Temperature °C (°F)

–20 (–4) –10 (14) 0 (32) 10 (50) 20 (68)

0 (0)

8 (5)

16 (9.9)

0 ms 0 ms 0 ms 0 ms 0 ms

37.136 ms 27.391 ms 17.646 ms 7.9012 ms 7.9012 ms

74.272 ms 54.782 ms 35.292 ms 15.802 ms 15.802 ms

Vehicle speed km/h (MPH) 24 (14.9) 32 (19.9) 111.41 ms 82.173 ms 52.938 ms 23.704 ms 23.704 ms

126.66 ms 99.65 ms 72.64 ms 45.63 ms 45.63 ms

40 (24.9)

48 (29.8)

56 (34.8)

141.91 ms 117.13 ms 92.341 ms 67.556 ms 67.556 ms

163.59 ms 135.96 ms 108.34 ms 80.711 ms 80.711 ms

185.26 ms 154.8 ms 124.33 ms 93.867 ms 93.867 ms

Judgment value of timer after engine starting t = 451056 ms – 25870 ms × Ti Ti : The lowest coolant temperature after engine start Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Engine coolant temperature

Threshold Value ≥ 20 °C (68 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AB:DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION 1. OUTLINE OF DIAGNOSIS Detect the malfunction of the engine coolant temperature sensor characteristics. Memorize the engine coolant temperature and fuel temperature at the last engine stop, and use them to judge as NG when the engine coolant temperature does not decrease when it should.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters Battery voltage Refueling from the last engine stop till the current engine start Fuel level Engine coolant temperature at the last engine stop

Enable Conditions ≥ 10.9 V None ≥ 15 2 (3.96 US gal, 3.3 Imp gal) ≥ 72 °C (161.6 °F)

4. GENERAL DRIVING CYCLE Perform the diagnosis only once after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Engine coolant temperature at the last engine stop — Minimum engine coolant temperature after the engine start Fuel temperature at the last engine stop — fuel temperature Intake air temperature — fuel temperature Fuel temperature

Threshold Value < 2.5 °C (36.5 °F)

≥ 5 °C (41 °F) < 2.5 °C (36.5 °F) < 35 °C (95 °F)

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Engine coolant temperature at the last engine stop — Minimum engine coolant temperature after the engine start

Threshold Value ≥ 2.5 °C (36.5 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AC:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE) 1. OUTLINE OF DIAGNOSIS Detect malfunctions of the thermostat function. Judge as NG when the engine coolant temperature is lower than the estimated engine coolant temperature and the difference between them is large. Judge as OK when the engine coolant temperature becomes to 75°C (167°F), and the difference is small, before judging NG.

2. COMPONENT DESCRIPTION (8)

(2)

(2)

(7)

(6)

(5)

(4)

(9)

(1) (3) EN-01692

(1) (2) (3)

Valve Spring Stopper

(4) (5) (6)

Piston Guide Rubber seal

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(7) (8) (9)

Stop ring Wax element Jiggle valve

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Estimate ambient temperature Thermostat malfunction diagnosis Engine coolant temperature at engine starting Estimated coolant temperature Engine coolant temperature (Estimated – Measured) Engine coolant temperature Vehicle speed

Threshold Value ≥ 10.9 V ≥ –7 °C (19.4 °F) Incomplete < 55 °C (131 °F) ≥ 73 °C (163.4 °F) ≤ 73 °C (163.4 °F) > 25 °C (77 °F) ≥ 30 km/h (18.6 MPH)

Time Needed for Diagnosis:64 ms × 3 time(s) × 152 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Estimate ambient temperature Thermostat malfunction diagnosis Engine coolant temperature at engine starting Engine coolant temperature (Estimated – Measured) Engine coolant temperature

Threshold Value ≥ 10.9 V ≥ –7 °C (19.4 °F) Incomplete < 55 °C (131 °F) ≥ 73 °C (163.4 °F) ≤ 25 °C (77 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AD:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of sensor. Judge as NG, when the element voltage is out of the specified range.

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Input voltage (+) or Input voltage (–) or |Input voltage (+) – Input voltage (–)|

Threshold Value < 1.128 V < 0.23 V < 0.644 V

Time Needed for Diagnosis: Input voltage (+): 1000 ms Input voltage (–): 1000 ms |Input voltage (+) – Input voltage (–)|: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Input voltage (+) Input voltage (–) |Input voltage (+) – Input voltage (–)|

Threshold Value ≥ 1.128 V ≥ 0.23 V ≥ 0.644 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AE:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of sensor. Judge as NG, when the element voltage is out of the specified range.

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Input voltage (+) or Input voltage (–)

Threshold Value > 3.589 V > 3.541 V

Time Needed for Diagnosis: Input voltage (+): 1000 ms Input voltage (–): 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Input voltage (+) Input voltage (–)

Threshold Value ≤ 3.589 V ≤ 3.541 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AF:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect the slow response of front oxygen (A/F) sensor. Front oxygen (A/F) sensor cover has some ventilation holes for exhaust gas. Clogged ventilation holes are diagnosed. When the holes are clogged, the A/F output variation becomes slow comparing with the actual A/F variation because oxygen which reaches the zirconia layer is insufficient. Therefore, if the sensor cover holes are clogged, the rich to lean judgment in the ECM is delayed when the actual change from rich to lean occurs. Judge as NG when the actual movement in comparison to the ECM control amount is slow.

(2)

(3)

(1) EN-01694

(1)

Cover

(2)

Zirconia

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(3)

Clogging

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Atmospheric pressure Closed loop control with main feedback Front oxygen (A/F) sensor impedance Elapsed time after starting the engine Engine coolant temperature Engine speed Vehicle speed Amount of intake air Engine load Learning value of EVAP conc. during purge Total time of operating canister purge

Enable Conditions ≥ 1024 ms ≥ 10.9 V > 75 kPa (563 mmHg, 22.2 inHg) Operation 0 Ω — 50 Ω ≥ 120000 ms ≥ 72 °C (161.6 °F) 1000 rpm — 3200 rpm 10 km/h — 120 km/h (6.2 MPH — 74.6 MPH) 10 g/s — 31 g/s (0.35 oz/s — 1.09 oz/s) < 0.02 g/rev (0 oz/rev) < 0.2 ≥ 19.9 s

4. GENERAL DRIVING CYCLE Perform diagnosis only once at a constant speed of 10 km/h — 120 km/h (6.2 MPH — 74.6 MPH) 120000 ms or more after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD Calculate faf difference every 32 ms × 4 , and the λ value difference. Calculate the diagnosis value after calculating 820 time(s). • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria parafca = td2faf/td2lmd where, td2faf (N) = td2faf (n–1) + |d2faf (n)| td2lmd (N) = td2lmd (n–1) + |d2lmd (n)| add up to 32 ms × 4 × 820 time(s). d2faf (n) = (faf (n) – faf (n–1)) – (faf (n–1) – faf (n–2)) d2lmd (n) = (lmd (n) – lmd (n–1)) – (lmd (n–1) – lmd (n–2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds

Threshold Value > 0.379

Time Needed for Diagnosis:32 ms × 4 × 820 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria parafca = td2faf/td2lmd

Threshold Value ≤ 0.379

where, td2faf (N) = td2faf (n–1) + |d2faf (n)| td2lmd (N) = td2lmd (n–1) + |d2lmd (n)| add up to 32 ms × 4 × 820 time(s). d2faf (n) = (faf (n) – faf (n–1)) – (faf (n–1) – faf (n–2)) d2lmd (n) = (lmd (n) – lmd (n–1)) – (lmd (n–1) – lmd (n–2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds

Time Needed for Diagnosis: 32 ms × 4 × 820 time(s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AG:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect open circuits of the sensor. Judge as NG when the impedance of the element is large.

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Time of heater control duty at 70 % or more Front oxygen (A/F) sensor impedance.

Threshold Value ≥ 10.9 V ≥ 36000 ms > 500 Ω

Time Needed for Diagnosis: 5000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Front oxygen (A/F) sensor impedance.

Threshold Value ≥ 10.9 V ≤ 500 Ω

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AH:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect continuity NG of the oxygen sensor. If the oxygen sensor voltage reading is not within the probable range considering the operating conditions, judge as NG.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Used for abnormality judgment Secondary Parameters

Enable Conditions

High Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Low (1) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Low (2) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Current continuation time of the rear oxygen sensor heater Low (3) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Current continuation time of the rear oxygen sensor heater Fuel cut

Not in operation In operation < 5 time(s) Not in limit value ≥ 10.9 V ≥ 72 °C (161.6 °F) Not in operation In operation < 5 time(s) Not in limit value ≥ 10.9 V ≥ 72 °C (161.6 °F) ≥ 10 g/s (0.35 oz/s) Not in operation In operation < 5 time(s) Not in limit value ≥ 10.9 V ≥ 72 °C (161.6 °F) < 10 g/s (0.35 oz/s) ≥ 25000 ms Not in operation In operation < 5 time(s) Not in limit value ≥ 10.9 V ≥ 72 °C (161.6 °F) < 10 g/s (0.35 oz/s) ≥ 25000 ms Experienced

Used for normality judgment Secondary Parameters Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature

Enable Conditions Not in operation In operation < 5 time(s) Not in limit value ≥ 10.9 V ≥ 72 °C (161.6 °F)

4. GENERAL DRIVING CYCLE After starting the engine, continuously perform the diagnosis with the same engine condition.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria High Sensor output voltage Low Sensor output voltage

Threshold Value

DTC P0138

> 1.2 V P0137 < 0.03 V

Time Needed for Diagnosis: High: 2500 ms Low (1): 20000 ms Low (2): 150000 ms Low (3): Value from Map Map Fuel cut time (ms) Time Needed for Diagnosis (ms)

0 150000

2000 150000

10000 150000

Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria High Sensor output voltage Low Sensor output voltage

Threshold Value

DTC P0138

≤ 1.2 V P0137 ≥ 0.03 V

Time Needed for Diagnosis: High: Less than 1 s Low (1): Less than 1 s Low (2): Less than 1 s Low (3): Less than 1 s

AI: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0137.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AJ:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect the slow response of the oxygen sensor. Judge as NG if either the rich to lean response diagnosis or lean to rich response diagnosis is NG, and judge as OK if both are OK. [Rich → lean diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to rich to lean. If the measured response time is larger than the threshold value, it is NG. If it is smaller, it is OK. Response time calculation is categorized in two by voltage difference. • Response time in small voltage difference: Intermediate • Response time in large voltage difference: Wide 2. Judge as NG when the oxygen sensor voltage is large (rich) even after deceleration fuel cut has occurred. [Lean → rich diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to lean to rich. If the measured response time is larger than the threshold value, it is NG. 2. Judge as NG when the oxygen sensor voltage remains small when recovering from a deceleration fuel cut. Diagnostic method Measure the response time of the output change of the oxygen sensor when the A/F ratio changes to rich to lean. And Judge as NG when the measured response time is larger than the threshold value.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Rich → lean diagnosis response Secondary Parameters Battery voltage A/F main feedback control condition Deceleration fuel cut time of 5000 ms or more (intermediate) Deceleration fuel cut time of 5000 ms or more (wide) After fuel cut Estimated temperature of the rear oxygen sensor element Number of deceleration fuel cut

Enable Conditions ≥ 10.9 V Complete Experienced

≥ 2000 ms (Intermediate) ≥ 2000 ms (Wide) ≥ 450 °C (842 °F) (Intermediate) ≥ 450 °C (842 °F) (Wide) ≥ 1 time(s)

4. GENERAL DRIVING CYCLE Perform diagnosis once during deceleration fuel cut from a constant and high speed driving, when rear oxygen sensor is warmed up sufficiently. (Pay attention to the oxygen sensor voltage for the timing of the deceleration.)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Intermediate When the oxygen sensor output voltage changes from 0.55 V (rich) to 0.15 V (lean), calculate the minimum response time for output change between 0.5 V and 0.2 V for the judgment criteria.

Diagnosis execution condition

(A) (B)

Rear oxygen sensor (V) (G) (C) (D) (E)

Fuel cut on deceleration (F) (H)

EN-05566

(A) (D) (G)

0.55 V 0.15 V Measure the response time.

(B) (E) (H)

0.5 V 0V Execute the malfunction judgment in 2000 ms from the recovery of fuel cut on deceleration.

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(C) (F)

0.2 V More than 5000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Wide When the oxygen sensor output voltage changes from 0.65 V (rich) to 0.05 V (lean), calculate the minimum response time for output change between 0.6 V and 0.1 V for the judgment criteria.

Diagnosis execution condition

(A) (B)

Rear oxygen sensor (V) (G) (C) (D) (E)

Fuel cut on deceleration (F) (H)

EN-05566

(A)

0.65 V

(B)

0.6 V

(C)

0.1 V

(D) (G)

0.05 V Measure the response time.

(E) (H)

0V Execute the malfunction judgment in 2000 ms from the recovery of fuel cut on deceleration.

(F)

More than 5000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment 1) Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut. Response time (diagnosis value) > threshold value → abnormal NOTE: Perform NG judgment only during fuel cut, when exhaust gas apparently changes from rich → lean. Even without deceleration fuel cut, judge as OK if the value is below the threshold. 2) Judge as NG when the oxygen sensor voltage at a deceleration fuel cut is large. Judge as NG when oxygen sensor voltage is large even after a long period of deceleration fuel cut has completed. Judgment value (Intermediate) Malfunction Criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V or Longest time over 0.55 V

Threshold Value > 837 ms

≥ 2000 ms

Judgment value (Wide) Malfunction Criteria Shortest time change from rich (0.6 V O2 output) to lean (0.1 V) when voltage reduces from 0.65 V to 0.05 V or Longest time over 0.65 V

Threshold Value > Value from Map

≥ 2000 ms

Map Estimated temperature of rear oxygen sensor element when fuel cut starts °C (°F) Longest time in rich status after fuel cut (ms)

0 (32)

450 (842)

480 (896)

500 (932)

1000 (1832)

5000

5000

3000

2000

2000

Time Needed for Diagnosis: 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Normality Judgment 1) Regardless of a deceleration fuel cut, if the response time (diagnosis value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as a normal condition. Response time (diagnosis value) ≤ threshold value → normal 2) Do not judge as a normal condition. Judge as OK and clear the NG if the following conditions are established.

Judgment value (Intermediate) Malfunction Criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V

Threshold Value ≤ 837 ms

Judgment value (Wide) Malfunction Criteria Shortest time change from rich (0.6 V O2 output) to lean (0.1 V) when voltage reduces from 0.65 V to 0.05 V

Threshold Value ≤ 2000 ms

Time Needed for Diagnosis: 1 time(s)

6. ENABLE CONDITION Lean → rich response diagnosis Secondary Parameters Battery voltage A/F main feedback control condition Deceleration fuel cut time is 6000 ms or more. After fuel cut Number of deceleration fuel cut

Enable Conditions ≥ 10.9 V Complete Experienced ≥ 2000 ms ≥ 1 time(s)

7. GENERAL DRIVING CYCLE Perform diagnosis once during deceleration fuel cut from a constant and high speed driving, when rear oxygen sensor is warmed up sufficiently. (Pay attention to the oxygen sensor voltage for the timing of the deceleration.)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

8. DIAGNOSTIC METHOD When the oxygen sensor output voltage changes from 0.25 V (lean) to 0.55 V (rich), calculate the minimum response time for output change between 0.3 V and 0.5 V for the judgment criteria.

Diagnosis execution condition

(H)

(A) (B)

Rear oxygen sensor (V)

(C) (D) (E)

(J)

(G) Fuel cut on deceleration (F) (I)

EN-05567

(A) (D) (G)

0.55 V 0.25 V More than 120000 ms

(J)

Judge NG when the voltage of rear oxygen sensor is 0.25 V or less for 120000 ms or more after recovery of fuel cut on deceleration.

(B) (E) (H)

0.5 V 0V Measure the response time (diagnostic value).

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(C) (F) (I)

0.3 V More than 5 seconds Execute the malfunction judgment in 4000 ms from the recovery of fuel cut on deceleration.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment 1) Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut. Response time (diagnosis value) > threshold value → abnormal 2) If the oxygen sensor voltage is small after recovering from a deceleration fuel cut, and remains small, judge as NG. Judgment Value Malfunction Criteria Shortest time change from lean (0.3 V O2 output) to rich (0.5 V) when voltage changes from 0.25 V to 0.55 V or Longest time under 0.25 V

Threshold Value > 4000 ms

≥ 120000 ms

Time Needed for Diagnosis: 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment 1) Regardless of a deceleration fuel cut, if the response time (diagnosis value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as a normal condition. Response time (diagnosis value) ≤ threshold value → normal 2) Do not judge as a normal condition. Judge as OK and clear the NG if the following conditions are established.

Judgment Value Malfunction Criteria Shortest time change from lean (0.3 V O2 output) to rich (0.5 V) when voltage changes from 0.25 V to 0.55 V

Threshold Value ≤ 4000 ms

Time Needed for Diagnosis: 1 time(s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AK:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2) 1. OUTLINE OF DIAGNOSIS Detect the rear oxygen sensor open or short circuit. Judge as NG when the rear oxygen sensor voltage can be determined to be abnormal considering conditions such as intake air amount, engine coolant temperature, main feedback control and deceleration fuel cut.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

3. ENABLE CONDITION (USED ONLY FOR MALFUNCTION JUDGMENT) Secondary Parameters Closed loop control at the rear oxygen sensor Target output voltage of rear oxygen sensor Amount of intake air Engine coolant temperature Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Deceleration fuel cut of 5000 ms or more.

Enable Conditions In operation ≥ 0.55 V + 0.05 V ≥ 10 g/s (0.35 oz/s) ≥ 72 °C (161.6 °F) < 5 time(s) Not in limit value ≥ 10.9 V Experienced

4. GENERAL DRIVING CYCLE Perform the diagnosis once after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Minimum output voltage or Maximum output voltage

Threshold Value > 0.15 V < 0.55 V

Time Needed for Diagnosis: 200000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Threshold Value Diagnosis of the rear oxygen sensor volt- Incomplete age low side Minimum output voltage ≤ 0.15 V Maximum output voltage ≥ 0.55 V

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AL:DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of rear oxygen sensor heater. While observing the engine condition, judge as NG if the rear oxygen sensor impedance is great.

2. COMPONENT DESCRIPTION

(1)

(2)

(3)

(4)

(5)

EN-07655

(1) (2)

Element cover (outer) Element cover (inner)

(3) (4)

Sensor element Ceramic heater

(5)

Sensor housing

3. ENABLE CONDITIONS Secondary Parameters Battery voltage Elapsed time after starting the engine Engine coolant temperature A/F sensor element impedance A/F sensor heater control duty Rear oxygen sensor heater control duty

Enable Conditions ≥ 10.9 V ≥ 1000 ms ≥ 72 °C (161.6 °F) ≤ 50 Ω ≤ 75 % < 70 %

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after 1000 ms seconds or more have passed since the engine started.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output terminal for heater characteristics fault detection

Threshold Value Low

Time Needed for Diagnosis: 4 ms × 2500 time (s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output terminal for heater characteristics fault detection

Threshold Value High

Time Needed for Diagnosis: 4 ms × 2500 time (s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AM:DTC P0171 SYSTEM TOO LEAN (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect fuel system malfunction by the amount of main feedback control. DIAGNOSTIC METHOD Fuel system is diagnosed by comparing the target air fuel ratio calculated by ECM with the actual air fuel ratio measured by sensor.

2. ENABLE CONDITION Secondary Parameters A/F main learning system Engine coolant temperature Engine load change Engine load

Enable Conditions In operation ≥ 72 °C (161.6 °F) < 0.02 g/rev (0 oz/rev) ≥ Value of Map 1

Map 1 Engine speed (rpm)

Idling

700

1200

1600

2000

2400

2800

3200

3600

4000

4400

na

0.230 (0.01)

0.217 (0.01)

0.213 (0.01)

0.210 (0.01)

0.210 (0.01)

0.220 (0.01)

0.223 (0.01)

0.240 (0.01)

0.252 (0.01)

0.261 (0.01)

Measured value (g (oz)/rev)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment Compare the diagnosed value (fsobd) with the threshold value, and if a condition meeting the malfunction criteria below continues for 10 s × 5 time(s) or more, judge that there is a fault in the fuel system. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf In this case: sglmd = measured lambda

Threshold Value ≥ Value from Map 2

tglmda = target lambda faf = Main feedback compensation coefficient (every 64 ms) flaf = main feedback learning compensation coefficient

Map 2 Amount of air (g (oz)/s) fsobdL1 (%)

0 (0) 1.4

2.34375 (0.08) 1.4

4.6875 (0.17) 1.368623

7.03125 (0.25) 1.319185

9.375 (0.33) 1.26975

11.71875 (0.41) 1.265

14.0625 (0.5) 1.265

Time Needed for Diagnosis: 10 s × 5 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf

Threshold Value < 1.2

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AN:DTC P0172 SYSTEM TOO RICH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect fuel system malfunction by the amount of main feedback control. Diagnostic method Fuel system is diagnosed by comparing the target air fuel ratio calculated by ECM with the actual air fuel ratio measured by sensor.

2. ENABLE CONDITION Secondary Parameters A/F main learning system Engine coolant temperature Engine load change Learning value of EVAP conc. Cumulative time of canister purge after engine start Continuous period after canister purge starting Engine load

Enable Conditions In operation ≥ 72 °C (161.6 °F) ≤ 0.02 g/rev (0 oz/rev) < 0.1 ≥ 20 s ≥ 29884 ms ≥ Value of Map 1

Map 1 Engine speed (rpm)

Idling

700

1200

1600

2000

2400

2800

3200

3600

4000

4400

na

0.230 (0.01)

0.217 (0.01)

0.213 (0.01)

0.210 (0.01)

0.210 (0.01)

0.220 (0.01)

0.223 (0.01)

0.240 (0.01)

0.252 (0.01)

0.261 (0.01)

Measured value (g (oz)/rev)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment Compare the diagnosed value (fsobd) with the threshold value, and if a condition meeting the malfunction criteria below continues for 10 s × 5 time(s) or more, judge that there is a fault in the fuel system. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf In this case: sglmd = measured lambda tglmda = target lambda faf = Main feedback compensation coefficient (every 64 ms) flaf = main feedback learning compensation coefficient

Threshold Value < Value of Map 2

Map 2 Amount of air (g (oz)/s) fsobdL1 (%)

0 (0) 0.6

2.34375 (0.08) 0.6

4.6875 (0.17) 0.63137

7.03125 (0.25) 0.68082

9.375 (0.33) 0.71025

11.71875 (0.41) 0.72525

14.0625 (0.5) 0.73025

Time Needed for Diagnosis: 10 s × 5 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK when the malfunction criteria below are met for 10 seconds. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf

Threshold Value ≥ 0.8

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AO:DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect faults in the fuel temperature sensor output properties. Diagnosis is performed in two methods (drift diagnosis and stuck diagnosis). If either is NG, judge as NG. If both are OK, Judge as OK and clear the NG. Drift Diagnosis Normally fuel temperature is lower than engine coolant temperature. When the fuel temperature becomes higher than the engine coolant temperature, the range is considered to be shifted, and judged as NG. Stuck Diagnosis As the engine warms up (cumulative amount of intake air after starting is large), if the fuel temperature which should rise does not, determine as being stuck and NG.

2. COMPONENT DESCRIPTION

(A)

(B)

EN-01700

(A)

Resistance value (Ω)

(B)

Fuel temperature °C (°F)

3. ENABLE CONDITION DRIFT DIAGNOSIS Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Fuel level Elapsed time after starting the engine Engine coolant temperature – Engine coolant temperature at engine start Fuel temperature – Engine coolant temperature Battery voltage

Threshold Value ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) ≥ 20 s > 10 °C (50 °F) ≥ 10 °C (50 °F) ≥ 10.9 V

Time Needed for Diagnosis: 120 s Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Fuel level Elapsed time after starting the engine Engine coolant temperature – Engine coolant temperature at engine start Fuel temperature – Engine coolant temperature Battery voltage Engine coolant temperature

Threshold Value ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) ≥ 20 s > 10 °C (50 °F) < 10 °C (50 °F) ≥ 10.9 V < 70 °C (158 °F)

Time Needed for Diagnosis: Less than 1 second

6. ENABLE CONDITION Stuck Diagnosis Secondary Parameters Elapsed time after starting the engine Battery voltage

Enable Conditions ≥ 20000 ms ≥ 10.9 V

7. GENERAL DRIVING CYCLE Perform the diagnosis continuously 20 seconds after starting engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

8. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Accumulated amount of intake air Fuel temperature difference between Max. and Min.

Threshold Value ≥ 551043 g (19435.29 oz) < 2 °C (35.6 °F)

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Fuel temperature difference between Max. and Min.

Threshold Value ≥ 2 °C (35.6 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AP:DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A)

(B)

EN-01700

(A)

Resistance value (Ω)

(B)

Fuel temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value < 0.573 V ≥ 10.9 V

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value ≥ 0.573 V ≥ 10.9 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AQ:DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A)

(B)

EN-01700

(A)

Resistance value (Ω)

(B)

Fuel temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value ≥ 4.716 V ≥ 10.9 V

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value < 4.716 V ≥ 10.9 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AR:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value ≤ 0.926 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value > 0.926 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AS:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value ≥ 4.858 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value < 4.858 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AT:DTC P0230 FUEL PUMP PRIMARY CIRCUIT 1. OUTLINE OF DIAGNOSIS Detect the malfunction of fuel pump control unit. Judge as NG when the NG signal is sent through a diagnostic line coming from the fuel pump control unit. Fuel pump control unit detects the open or short circuit malfunction for each line, and then sends NG signals if one of them is found NG.

2. COMPONENT DESCRIPTION

+B FP+

FPC (1)

(3)

(2) DI

(4)

FP-

E

E EN-01771

(1) (2)

Engine control module (ECM) Fuel pump control unit

(3)

Fuel pump

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Battery

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Fuel pump control Fuel pump control unit output diagnosis signal Fuel level

Threshold Value ≥8V ≥ 180000 ms ON Low ≥ 10 2 (2.64 US gal, 2.2 Imp gal)

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Fuel pump control Fuel pump control unit output diagnosis signal Fuel level

Threshold Value ≥8V ≥ 180000 ms ON High ≥ 10 2 (2.64 US gal, 2.2 Imp gal)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AU:DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect the malfunction of wastegate control solenoid valve function. Judge as NG when becoming high wastegate pressure.

2. COMPONENT DESCRIPTION

(1)

EN-01772

(1)

Coil

3. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria

Threshold Value ≥ Value from Map

Intake manifold pressure

Map

2000

70.6 (530, 20.9) 194.6 (1460, 57.5)

Atmospheric pressure (kPa (mmHg, inHg)) 93.3 90.6 84 77.3 (700, (680, (630, (580, 27.6) 26.8) 24.8) 22.8) 194.6 194.6 194.6 194.6 (1460, (1460, (1460, (1460, 57.5) 57.5) 57.5) 57.5)

197.3 (1480, 58.3)

197.3 (1480, 58.3)

197.3 (1480, 58.3)

197.3 (1480, 58.3)

197.3 (1480, 58.3) 193.9 (1454, 57.3) 188.3 (1413, 55.6) 182.6 (1370, 53.9)

197.3 (1480, 58.3) 194.7 (1461, 57.5) 190.9 (1432, 56.4)

197.3 (1480, 58.3) 195.6 (1467, 57.8)

96 (720, 28.3) 194.6 (1460, 57.5)

97.3 (730, 28.7) 194.6 (1460, 57.5)

197.3 (1480, 58.3) 196.4 (1474, 58)

197.3 (1480, 58.3) 197.3 (1480, 58.3) 197.3 (1480, 58.3)

197.3 (1480, 58.3) 197.3 (1480, 58.3) 197.3 (1480, 58.3)

197.3 (1480, 58.3) 197.3 (1480, 58.3) 197.3 (1480, 58.3)

193.5 (1451, 57.1)

196 (1471, 57.9)

198.6 (1490, 58.7)

198.6 (1490, 58.7)

198.6 (1490, 58.7)

197.3 (1480, 58.3) 197.3 (1480, 58.3) 197.3 (1480, 58.3) 198.6 (1490, 58.7)

187 (1403, 55.2)

191.3 (1435, 56.5)

195.6 (1468, 57.8)

200 (1500, 59.1)

200 (1500, 59.1)

200 (1500, 59.1)

200 (1500, 59.1)

172.2 (1292, 50.9)

178.3 (1338, 52.7)

184.4 (1383, 54.4)

161.8 (1214, 47.8) 155.2 (1164, 45.8) 149 (1118, 44)

169.6 (1273, 50.1) 164.9 (1237, 48.7)

177.4 (1331, 52.4)

190.4 (1429, 56.2) 185.2 (1390, 54.7)

196.5 (1474, 58) 193 (1448, 57)

198.2 (1487, 58.5) 196.5 (1474, 58)

200 (1500, 59.1) 200 (1500, 59.1)

174.7 (1311, 51.6)

184.4 (1384, 54.5)

194.2 (1457, 57.4)

198.6 (1490, 58.7)

203.1 (1523, 60)

200 (1500, 59.1) 200 (1500, 59.1) 203.9 (1530, 60.2)

160.8 (1206, 47.5)

172.6 (1295, 51)

184.4 (1383, 54.5)

196.2 (1472, 57.9)

200.7 (1506, 59.3)

205.2 (1540, 60.6)

207.9 (1560, 61.4)

6000

138.3 (1038, 40.8)

151.7 (1138, 44.8)

165.1 (1239, 48.8)

178.5 (1339, 52.7)

6400

137 (1028, 40.5)

150.3 (1128, 44.4)

163.5 (1227, 48.3)

176.8 (1326, 52.2)

191.9 (1440, 56.7) 190 (1426, 56.1)

196.4 (1473, 58) 194.5 (1459, 57.4)

200.8 (1507, 59.3) 198.9 (1492, 58.7)

2400

2800

3200

3600

Engine speed (rpm)

64 (480, 18.9) 194.6 (1460, 57.5)

4000

4400

4800

5200

5600

Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

GD(H4DOTC)-88

205.3 (1540, 60.6) 203.3 (1525, 60) kPa (mmHg, inHg)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Intake manifold pressure

Threshold Value < Value from Map – 20 kPa (150 mmHg, 5.9 inHg)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AV:DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” LOW 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the wastegate control solenoid valve. Judge as NG when the terminal output voltage remains Low during outputting the duty signal.

2. COMPONENT DESCRIPTION

(1)

EN-01772

(1)

Coil

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 1 second

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting the engine.

5. DIAGNOSTIC METHOD Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Terminal output voltage Duty ratio of wastegate control

Threshold Value Low < 75%

Time Needed for Diagnosis:4 ms × 640 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal output voltage

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AW:DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID “A” HIGH 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the wastegate control solenoid valve. Judge as NG when the terminal output voltage remains Low or High during outputting the duty signal.

2. COMPONENT DESCRIPTION

(1)

EN-01772

(1)

Coil

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 1 second

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting the engine.

5. DIAGNOSTIC METHOD Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Terminal output voltage Duty ratio of wastegate control

Threshold Value High ≥ 25%

Time Needed for Diagnosis:4 ms × 640 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal output voltage

Threshold Value Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AX:DTC P0301 CYLINDER 1 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS Detect the presence of misfire occurrence. (Revolution fluctuation method) Monitoring Misfire which influences exhaust deterioration (1.5 times of FTP) and catalyst damage is made obligatory by the law. Misfire affecting these two has two patterns below. : • Intermittent misfire (The same cylinder misfires in random, or different cylinders misfire in random.): FTP 1.5 times misfire • Every time misfire (The same cylinder misfires every time.): FTP 1.5 times misfire, Catalyst damage misfire The following detecting methods are adopted for these detection. 1) Intermittent misfire: FTP 1.5 times misfire • 180° Interval Difference Method (MT: 1,800 rpm or less, AT: None) • 360° Interval Difference Method (whole range) • 720° Interval Difference Method (3,000 rpm or more) 2) Misfire every time: FTP 1.5 times misfire, Catalyst damage misfire • 360° Interval Difference Method

2. ENABLE CONDITION Secondary Parameters All secondary parameters enable conditions Intake manifold pressure change at 180° CA Throttle position variation for 16 ms Fuel shut-off function Fuel level Vehicle dynamic control or AT torque control Evaporative system leak check Engine speed Intake manifold pressure Battery voltage Fuel parameter determination Elapsed time after starting the engine Engine speed variation for 32 ms

Enable Conditions ≥ 1024 ms < Value of Map 1 < 14 ° Not in operation ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) Not in operation Not in operation 550 rpm — 6700 rpm ≥ Value from Map 2 ≥8V Not extremely low volatility ≥ 0 ms < 1000 rpm

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Map 1 rpm kPa (mmHg, inHg)

700

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

6700

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

13.3 (100, 3.9)

Map 2 • Tumble generator valve open Vehicle speed < 64 km/h (39.8 MPH) rpm kPa (mmHg, inHg)

700

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

6700

28.8 (216, 8.5)

24.9 (187, 7.4)

21.1 (158, 6.2)

21.7 (163, 6.4)

22.3 (167, 6.6)

23.1 (173, 6.8)

28.5 (214, 8.4)

28.4 (213, 8.4)

31.6 (237, 9.3)

32.5 (244, 9.6)

37.1 (278, 10.9)

41.9 (314, 12.4)

46.9 (352, 13.9)

51.1 (383, 15.1)

2500 32.1 (241, 9.5)

3000 31.6 (237, 9.3)

3500 36.7 (275, 10.8)

4000 35.1 (263, 10.4)

4500 38.3 (287, 11.3)

5000 39.2 (294, 11.6)

5500 43.7 (328, 12.9)

6000 48.5 (364, 14.3)

6500 53.6 (402, 15.8)

6700 54.7 (410, 16.1)

Vehicle speed ≥ 68 km/h (42.3 MPH) rpm kPa (mmHg, inHg)

700 25.1 (188, 7.4)

1000 24.8 (186, 7.3)

1500 31.6 (237, 9.3)

2000 33.1 (248, 9.8)

• Tumble generator valve closed Vehicle speed < 64 km/h (39.8 MPH) rpm kPa (mmHg, inHg)

700

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

6700

28.8 (216, 8.5)

24.9 (187, 7.4)

21.1 (158, 6.2)

21.7 (163, 6.4)

22.3 (167, 6.6)

23.1 (173, 6.8)

28.5 (214, 8.4)

28.4 (213, 8.4)

31.6 (237, 9.3)

32.5 (244, 9.6)

37.1 (278, 10.9)

41.9 (314, 12.4)

46.9 (352, 13.9)

51.1 (383, 15.1)

Vehicle speed ≥ 68 km/h (42.3 MPH) rpm kPa (mmHg, inHg)

700

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

6700

25.1 (188, 7.4)

24.8 (186, 7.3)

31.6 (237, 9.3)

33.1 (248, 9.8)

32.1 (241, 9.5)

31.6 (237, 9.3)

36.7 (275, 10.8)

35.1 (263, 10.4)

38.3 (287, 11.3)

39.2 (294, 11.6)

43.7 (328, 12.9)

48.5 (364, 14.3)

53.6 (402, 15.8)

54.7 (410, 16.1)

3. GENERAL DRIVING CYCLE • If conditions are met, it is possible to detect the misfires from idling to high engine speed. However, to avoid excessive load or harm to the engine, perform diagnosis at idle. • Perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. DIAGNOSTIC METHOD When a misfire occurs, the engine speed will decreased and the crankshaft position speed will change. Calculate the interval difference value (diagnostic value) from crankshaft position speed by the following formula, and judge whether a misfire is occurring or not comparing the calculated result with judgment value. Counting the number of misfires. If the misfire ratio is higher during 1000 revs. or 200 revs., Judge corresponding cylinders as NG. Diagnostic value calculation (Calculate from angle speed) →

Misfire detection every single ignition NG judgment (Misfire occurrence judg(Compare diagnostic value with judg- ment required by the law) (Compare ment value) → number of misfire with judgment) • 180° Interval Difference Method • 360° Interval Difference Method • 720° Interval Difference Method

• FTP 1.5 times misfire NG judgment • Catalyst damage misfire NG judgment

As shown in the following figure, pick a cylinder as the standard and name it omg 0. And the former crankshaft position speed is named omg 1, the second former crankshaft position speed is named omg 2, the third is named omg 3, etc.

(A)

(B)

#3

#2

#4

#1

#3

#2

#4

#1

#3

omg7

omg6

omg5

omg4

omg3

omg2

omg1

omg0

#2

EN-01774

(A)

Ignition order

(B)

Crankshaft position speed

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

180° Interval Difference Method Diagnostic domg 180 = (omg 1 – omg 0) – (omg 5 – omg 1)/4 value Judge as a misfire in the following cases. • domg 180 > judgment value of positive side • domg 180 ≤ judgment value of negative side (Judgment value before 180° CA)

domg180 Threshold valve (positive number)

domg180

Threshold valve (negative number)

Judged as misfire.

EN-02877

360° Interval Difference Method Diagnostic value Misfire judgment

domg 360 = (omg 1 – omg 0) – (omg 3 – omg 2) domg 360 > Judgment value → Judge as misfire

domg360 Threshold valve

domg360

Judged as misfire.

EN-03273

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

720° Interval Difference Method Diagnostic value Misfire judgment

domg 720 = (omg 1 – omg 0) – (omg 5 – omg 4) domg 720 > Judgment value → Judge as misfire

domg720

Threshold valve

domg720

Judged as misfire.

EN-03274

• FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas) • Abnormality Judgment Judgment Value (Judge that malfunction occurs when the misfire ratio is high in 1000 engine revs.) Malfunction Criteria FTP emission judgment value

Threshold Value ≥ 30 × 100/2000% in 1000 revs.

Time Needed for Diagnosis: 1000 engine revs. Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judgment Value Malfunction Criteria FTP emission judgment value

Threshold Value < 30 × 100/2000% in 1000 revs.

Time Needed for Diagnosis: 1000 engine revs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Catalyst damage misfire (Misfire occurrence level damaging catalyst) • Abnormality Judgment Judgment Value Malfunction Criteria Catalyst damage misfire judgment value

Threshold Value ≥ Value of Map 3

Map 3

Engine speed (rpm)

700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 6700

0.2 (0.01)

0.4 (0.01)

0.6 (0.02)

0.8 (0.03)

126 126 119 109 99 92 83 59 51 47 46 44 43 43

109 109 100 77 74 74 63 52 47 47 46 44 43 43

99 97 87 77 48 49 37 34 29 29 28 27 26 26

90 88 77 62 38 33 23 23 21 20 20 20 20 20

Intake air (g(oz)/rev) 1 1.2 (0.04) (0.04) 85 78 72 49 33 31 20 20 20 20 20 20 20 20

77 72 72 37 31 31 20 20 20 20 20 20 20 20

1.4 (0.05)

1.6 (0.06)

1.8 (0.06)

2 (0.07)

77 72 72 34 29 27 20 20 20 20 20 20 20 20

77 72 61 31 27 26 20 20 20 20 20 20 20 20

77 72 61 27 26 24 20 20 20 20 20 20 20 20

77 72 61 20 20 20 20 20 20 20 20 20 20 20

Time Needed for Diagnosis: 200 engine revs. Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judgment Value Malfunction Criteria Catalyst damage misfire judgment value

Threshold Value < Value of Map 3

Time Needed for Diagnosis: 200 engine revs.

AY:DTC P0302 CYLINDER 2 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

AZ:DTC P0303 CYLINDER 3 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

BA:DTC P0304 CYLINDER 4 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BB:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of knock sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(4)

(5)

(2)

(A)

(3)

EN-01707

(A)

To knock sensor harness

(1) (2)

Case Weight

(3) (4)

Piezoelectric element Nut

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4DOTC)-98

(5)

Resistance

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.243 V

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.243 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BC:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of knock sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(4)

(5)

(2)

(A)

(3)

EN-01707

(A)

To knock sensor harness

(1) (2)

Case Weight

(3) (4)

Piezoelectric element Nut

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4DOTC)-100

(5)

Resistance

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.709 V

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.709 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BD:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the crankshaft position sensor. Judge as NG when the crank signal is not input even though the starter was rotated.

2. COMPONENT DESCRIPTION

50 CA

50 CA

50 CA

50 CA

50 CA

(A)

50 CA (B) #3BTDC10 CA

#1BTDC10 CA

#2BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(C)

10 C

30 C 30 C

EN-03269

(A)

Camshaft signal (RH)

(B)

Camshaft signal (LH)

(C)

Crankshaft signal

(1)

(3)

(2)

(1)

Crankshaft position sensor

EN-01780

(2)

Crank sprocket

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4DOTC)-102

(3)

Crankshaft half-turn

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Starter switch Crankshaft position sensor signal Battery voltage

Threshold Value ON Not detected ≥8V

Time Needed for Diagnosis: 3000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Crankshaft position sensor signal Battery voltage

Threshold Value Input exists ≥8V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BE:DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect for faults in crankshaft position sensor output properties. Judge as NG when there is a problem in the number of crankshaft signals for every revolution.

2. COMPONENT DESCRIPTION

50 CA

50 CA

50 CA

50 CA

50 CA

(A)

50 CA (B) #3BTDC10 CA

#1BTDC10 CA

#2BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(C)

10 C

30 C 30 C

EN-03269

(A)

Camshaft signal (RH)

(B)

Camshaft signal (LH)

(C)

Crankshaft signal

(1)

(3)

(2)

(1)

Crankshaft position sensor

EN-01780

(2)

Crank sprocket

3. ENABLE CONDITION Secondary Parameters Battery voltage Engine speed

Enable Conditions ≥8V < 3000 rpm

GD(H4DOTC)-104

(3)

Crankshaft half-turn

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously under 3000 rpm engine speed.

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Cylinder number identification Amount of crank sensor signal during 1 rev.

Threshold Value Completed Not = 30

Time Needed for Diagnosis: 10 engine revs. Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Cylinder number identification Amount of crank sensor signal during 1 rev.

Threshold Value Completed = 30

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BF:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the camshaft position sensor. Judge as NG when the number of camshaft signals remains abnormal.

2. COMPONENT DESCRIPTION

(D)

50 CA

50 CA

50 CA

50 CA

50 CA

(A)

50 CA (B) #1BTDC10 CA

#3BTDC10 CA

#2BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(C)

10 C

30 C 30 C EN-01853

(A) (D)

Camshaft signal (RH) Number of camshaft position signals = When normal, there will be 3 cam signals for every two engine revolutions.

(B)

Camshaft signal (LH)

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥8V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H4DOTC)-106

(C)

Crankshaft signal

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment 1 Judge as NG when the status where the number of camshaft position sensor signal in two engine revolutions is less than 3 time(s). Judgment Value Malfunction Criteria Amount of camshaft sensor signal during 2 revs.

Threshold Value < 3 time(s)

Time Needed for Diagnosis: Engine two revolutions × 50 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment 1 Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Camshaft position sensor signal

Threshold Value ≥ 3 time(s)

Time Needed for Diagnosis: Two engine revolutions • Abnormality Judgment 2 If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Starter Camshaft position sensor signal

Threshold Value ON No input

Time Needed for Diagnosis: 3000 ms • Normality Judgment 2 Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Camshaft position sensor signal

Threshold Value Input exists

Time Needed for Diagnosis: Less than 1 second

BG:DTC P0345 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0340.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BH:DTC P0365 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the camshaft position sensor. Judge as NG when the number of camshaft signals remains abnormal.

2. COMPONENT DESCRIPTION

Number of camshaft signal - 3 is normal at two engine revolution in a range of 0 CA - 0 CA. (A)

(B)

#1BTDC10 CA

#6BTDC10 CA

#3BTDC10 CA

#2BTDC10 CA

#5BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(C)

10 CA

30 CA

30 CA

EN-03092

(A)

Cam signal (RH)

(B)

Cam signal (LH)

(C)

Crankshaft signal

(1)

(3) (4)

(2)

EN-02190

(1)

Throttle

(2)

Camshaft plate

(3)

Detecting point

3. ENABLE CONDITIONS Secondary Parameters Battery voltage

Enable Conditions ≥8V

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(4)

Camshaft one revolution (engine two revolutions)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the status where the number of camshaft position sensor signal in two engine revolutions is less than 2 time(s). Judgment Value Malfunction Criteria Amount of camshaft sensor signal during 2 revs.

Threshold Value < 2 time(s)

Time Needed for Diagnosis: Engine two revolutions × 50 Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Camshaft position sensor signal

Threshold Value ≥ 2 time(s)

Time Needed for Diagnosis: Two engine revolutions

BI: DTC P0390 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0365.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the deterioration of the catalyst function. Though the front oxygen sensor output would change slowly with a new catalyst, the sensor output with a deteriorated catalyst becomes high and the inversion time is shortened. For this reason, the catalyst diagnosis is carried out by monitoring the front oxygen sensor output and comparing it with the front oxygen (A/F) sensor output.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(3)

(B)

(3)

(C)

(D)

EN-01713

(A)

Normal

(D)

Output waveform from the front oxygen sensor

(1)

Front oxygen (A/F) sensor

(B)

Deterioration

(C)

Output waveform from the front oxygen (A/F) sensor

(2)

Front oxygen sensor

(3)

Catalytic converter

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Battery voltage Atmospheric pressure Engine coolant temperature Estimated catalyst temperature Misfire detection every 200 rotations Learning value of evaporation gas density Sub feedback Evaporative system diagnosis Time of difference (< 0.10) between actual lambda and target lambda Vehicle speed Amount of intake air

Engine load change every 0.5 engine revs. Rear oxygen output change from 660 mV or less to 660 mV or more Elapsed time after starting the engine Purge execution calculated time

Enable Conditions ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 72 °C (161.6 °F) ≥ 540 °C (1004 °F) < 5 time(s) < 0.2 In operation Not in operation ≥ 1000 ms > 60 km/h (37.3 MPH) ≥ 6.5 g/s (0.23 oz/s) and < 50 g/s (1.76 oz/s) < 0.02 g/rev (0 oz/rev) Experienced after fuel cut ≥ 230 second ≥5s

4. GENERAL DRIVING CYCLE Perform the diagnosis only once at a constant speed of 60 km/h (37.3 MPH) or higher.

5. DIAGNOSTIC METHOD After the enable conditions have been established, calculate the front oxygen (A/F) sensor lambda value deviation cumulative value (Σ |(sglmdn – sglmdn–1 )|), and rear oxygen sensor output voltage deviation cumulative value (Σ |(ro2sadn – ro2sadn–1)|) in every 32 × 4 times. If the front oxygen (A/F) sensor lambda value deviation cumulative value (Σ |(sglmdn – sglmdn–1 )|) is the predetermined value or more, calculate the judgment value. • Abnormality Judgment If the duration of time while the following conditions are met is within the time indicated, judge as NG. Judgment Value Malfunction Criteria Σ |(ro2sadn – ro2sadn–1)| / Σ |(sglmdn – sglmdn–1)|

Threshold Value > 9.03

Time Needed for Diagnosis: 30 — 55 seconds Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is within the predetermined time. Judgment Value Malfunction Criteria Σ |(ro2sadn – ro2sadn–1)| / Σ |(sglmdn – sglmdn–1)|

Threshold Value ≤ 9.03

Time Needed for Diagnosis: 30 — 55 seconds

GD(H4DOTC)-111

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BK:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK) 1. OUTLINE OF DIAGNOSIS Check if there is a leakage in fuel system or not, and perform the function diagnosis of valve.

(3) (4) (1)

(5)

(2)

(6)

(16)

(15) (8)

(17)

(10) (9) (11)

(14)

(13)

(12)

(7) EN-05372

(1) (2) (3) (4) (5) (6)

Fuel gauge Intake manifold Throttle body Purge control solenoid valve Purge control solenoid valve 2 Engine control module (ECM)

(7) (8) (9) (10) (11) (12)

Canister Pressure control valve Drain valve Drain filter Shut-off valve Fuel temperature sensor

(13) (14) (15) (16) (17)

Fuel level sensor Fuel tank Fuel cut valve Fuel tank pressure sensor Vent valve

In this system diagnosis, check for leakage and valve function is conducted by changing the fuel tank pressure and monitoring the pressure change using the fuel tank pressure sensor. When in 0.04 inch diagnosis, perform in the order of mode Z → mode A → mode B → mode C and mode D; When in 0.02 inch diagnosis, perform in the order of mode A → mode B → mode C → mode D and mode E.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

0.04-inch Diagnosis

Mode Z

OK

Mode A

OK

Mode B

OK

Mode C

OK

OK

Mode D NG

Parge control solenoid velve2 blockade diagnosis

OK NG

Early OK Large leakage judgement

END

Cancel

NG

Mode Z Extend

NG OK

EN-05590

Mode Mode Z (Purge control solenoid valve opening failure diagnosis) Mode A (Estimated evaporation amount) Mode B (Sealed negative pressure, large leakage judgment) Mode C (Pressure increase check, advanced OK judgment)

Mode Description

Diagnosis Period

Perform purge control solenoid valve opening failure diagnosis from the size of tank pressure variation from diagnosis start.

0 ms + 3000 ms — 0 ms + 3000 ms + 13000 ms

Calculate the tank pressure change amount (P1).

10000 ms

Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank. If the tank pressure cannot be reduced, it is diagnosed as large leak.

0 — 10000 ms + 25000 ms

Wait until the tank pressure returns to the target (start level of P2 calculation). If the tank pressure does not become the value, make advanced OK judgment.

0 — 23635 ms

Mode D Calculate the tank pressure variation (P2), and obtain the diagnostic (Negative pressure variation value using P1 found in Mode A. measurement, evaporation leakPerform the evaporation diagnosis using the diagnostic value. age diagnosis)

0 ms + 10000 ms

Mode Table for Evaporative Emission Control System Diagnosis Mode Mode Z

Behavior of tank internal pressure under normal conditions Diagnostic item Roughly the same as barometric pressure (Same as 0 kPa Purge control solenoid valve is judged (0 mmHg, 0 inHg)) to be open.

Mode A

Pressure is in proportion to amount of evaporative emission.

Mode B

Negative pressure is formed due to intake manifold negative pressure

Mode C

Reaches target pressure

Mode D

Pressure change is small.

— Large leak

P0457 None P0457

— EVAP system large leak determination. [1.0 mm (0.04 in)]

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DTC

None P0442

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

0.02-inch Diagnosis

Mode A

OK

Mode B

OK

Mode C

OK

OK

Mode D

Mode E

Cancel Early OK 2 Cancel

END

Early OK 1 Cancel Cancel Cancel

EN-02871

Mode Mode A (0 point compensation)

Mode Description When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg).

Diagnosis Period 0 — Value of Map 1

Mode B (Negative pressure introduced)

Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank.

Mode C (Negative pressure maintained) Mode D (Negative pressure change calculated)

Wait until the tank pressure returns to the target (start level of P2 calculation).

Value from Map 3

Calculate the time it takes for the tank pressure to change to the Mode E shifting pressure. If the tank pressure does not change to the Mode E shifting pressure, make advanced OK judgment.

0 — 0 ms + Value from Map 4

Mode E (Evaporation generated amount calculation)

Calculate the amount of evaporation (P1).

GD(H4DOTC)-114

0 — Value of Map 2

0 — 0 ms + Value from Map 4 + Value from Map 5

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Map 1 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

10 9216

27, 7.13, 5.94 9216

43, 11.36, 9.46 7936

59.5, 15.72, 13.09 4736

10 21180

27, 7.13, 5.94 23924

43, 11.36, 9.46 24931

59.5, 15.72, 13.09 24931

10 51830

27, 7.13, 5.94 32722

43, 11.36, 9.46 18045

59.5, 15.72, 13.09 13071

Map 2 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

Map 3 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

Map4 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

10

20, 5.28, 4.4

30, 7.93, 6.6

40, 10.57, 8.8

50, 13.21, 11

200000

200000

200000

200000

200000

10

20, 5.28, 4.4

30, 7.93, 6.6

40, 10.57, 8.8

50, 13.21, 11

80000

70000

60000

60000

60000

60, 15.85, 13.2 200000

Map 5 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

60, 15.85, 13.2 60000

2. COMPONENT DESCRIPTION Pressure control solenoid valve PCV controls the fuel tank pressure to be equal to the atmospheric air pressure. Normally, the solenoid is set to OFF. The valve opens and closes mechanically in accordance with the pressure difference between tank and atmospheric air, or tank and canister. The valve is forcibly opened by setting the solenoid to ON at the time of diagnosis.

(a) (1)

(4)

(b)

(c)

(3)

(2)

EN-01715

(a)

Atmospheric pressure

(b)

Fuel tank

(c)

Canister

(1) (2)

Solenoid Diaphragm

(3)

Valve

(4)

Spring

GD(H4DOTC)-115

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Valve Operation and Air Flow In the figure below, divided by the diaphragm, the part above X is charged with atmospheric air pressure, and the part below X is charged with tank pressure. Also, the part above Y is charged with tank pressure, and the part below Y is charged with canister pressure. If the atmospheric air pressure port is A, tank pressure port is B, and canister pressure port is C, the air flows according to pressure difference from each port as shown in the table below.

A (a)

B

C

(b)

(c)

X

Y

X

EN-01716

(a)

Atmospheric pressure

(b)

Condition of pressure A < B (solenoid OFF) B < C (solenoid OFF) Solenoid ON

Fuel tank

(c)

Canister

Flow B→C C→B B←→C

When A < B (solenoid OFF)

A (a)

B

C

(b)

(c)

EN-01717

(a)

Atmospheric pressure

(b)

Fuel tank

GD(H4DOTC)-116

(c)

Canister

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

When B < C (solenoid OFF)

A (a)

B

C

(b)

(c)

(1) EN-01718

(a)

Atmospheric pressure

(1)

Valve

(b)

Fuel tank

(c)

Canister

When Solenoid is ON

A (a)

B

C

(b)

(c)

EN-01719

(a)

Atmospheric pressure

(b)

Fuel tank

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(c)

Canister

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Drain valve Drain valve controls the ambient air to be introduced to the canister.

EN-02293

GD(H4DOTC)-118

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION 0.04-inch Diagnosis Secondary Parameters Battery voltage Atmospheric pressure Total time of canister purge operation Learning value of evaporation gas density Engine speed Fuel tank pressure Intake manifold relative vacuum (relative pressure) Continuous time of the status where fuel level is 10.5 2 (2.77 US gal, 2.31 Imp gal) — 59.5 2 (15.72 US gal, 13.09 Imp gal) Closed air/fuel ratio control Fuel temperature Intake air temperature Pressure variation every one second Minimum pressure variation value every one second – Maximum pressure variation value every one second Fuel level variation every 128 ms Air fuel ratio Elapsed time after starting the engine or Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 120000 ms < 0.08 1050 rpm — 4000 rpm ≥ –4 kPa (–30 mmHg, –1.2 inHg) ≥ –13.3 kPa (–100 mmHg, –3.9 inHg) ≥ 37000 ms

In operation –10 °C (14 °F) — 45 °C (113 °F) ≥ –10 °C (14 °F) < 1.7 mmHg (Mode A) < 1.7 mmHg (Mode D) < 1.7 mmHg (Mode A) < 1.7 mmHg (Mode D) < Value of Map 6 0.76 — 1.25 ≥ 856 s ≥ 335 s and Vehicle speed 72 km/h (44.7 MPH) or more

Map 6 Fuel level (2, US gal, Imp gal)

10, 2.64, 2.2

20, 5.28, 4.4

25, 6.61, 5.5

30, 7.93, 6.6

43, 11.36, 9.46

45, 11.89, 9.9

50, 13.21, 11

60, 15.85, 13.2

Change (2, US gal, Imp gal)

4, 1.06, 0.88

5, 1.32, 1.1

6.5, 1.72, 1.43

4, 1.06, 0.88

5, 1.32, 1.1

5, 1.32, 1.1

6, 1.59, 1.32

8, 2.11, 1.76

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

0.02-inch Diagnosis Secondary Parameters At starting a diagnosis Evap. diagnosis Battery voltage Atmospheric pressure Time since last incomplete 0.02-inch leakage diagnosis When cancelling in mode A When cancelling in other than mode A Total time of canister purge operation Elapsed time after starting the engine Fuel temperature Continuous time of the status where fuel level is 10.5 2 (2.77 US gal, 2.31 Imp gal) — 59.5 2 (15.72 US gal, 13.09 Imp gal) Intake manifold relative vacuum (relative pressure) Fuel tank pressure Closed air/fuel ratio control Engine speed Vehicle speed During diagnosis Change of fuel level Pressure variation every one second Minimum pressure variation value every one second – Maximum pressure variation value every one second |Tank pressure variation every one second| Barometric pressure change

Enable Conditions Incomplete ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg)

> 120000 ms > 240000 ms ≥ 120000 ms ≥ 120 s –10 °C (14 °F) — 55 °C (131 °F) ≥ 37000 ms

≥ –13.3 kPa (–100 mmHg, –3.9 inHg) –0.7 kPa (–5 mmHg, –0.2 inHg) — 1.4 kPa (10.7 mmHg, 0.4 inHg) In operation 1050 rpm — 4000 rpm Continue the status of 50 km/h (31.1 MPH) — 510 km/h (316.9 MPH) for 125000 ms or more. ≤ Value of Map 7 < 0.1 kPa (0.44 mmHg, 0 inHg) < 0.1 kPa (0.51 mmHg, 0 inHg) (Mode D)

≤ 0.1 kPa (0.75 mmHg, 0 inHg) –0.5 kPa (–3.6 mmHg, –0.1 inHg) — 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode D) –0.3 kPa (–2.4 mmHg, –0.1 inHg) — 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode E)

Map 7 Fuel level (2, US gal, Imp gal)

10, 2.64, 2.2

20, 5.28, 4.4

25, 6.61, 5.5

30, 7.93, 6.6

43, 11.36, 9.46

45, 11.89, 9.9

50, 13.21, 11

60, 15.85, 13.2

Change (2, US gal, Imp gal)

4, 1.06, 0.88

5, 1.32, 1.1

6.5, 1.72, 1.43

4, 1.06, 0.88

5, 1.32, 1.1

5, 1.32, 1.1

6, 1.59, 1.32

8, 2.11, 1.76

4. GENERAL DRIVING CYCLE 0.04-inch Diagnosis • Perform the diagnosis only once, 335 seconds or more after starting the engine, at a constant speed of 72 km/h (45 MPH) or more. • Pay attention to the fuel temperature and fuel level. 0.02-inch Diagnosis • Perform the diagnosis after 125 seconds or more have elapsed at a constant engine speed of 50 km/h (31 MPH) or higher to judge as NG or OK. • If judgment cannot be made, repeat the diagnosis. • Pay attention to the fuel level.

GD(H4DOTC)-120

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD Purge control solenoid valve stuck open fault diagnosis DTC P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) Purpose of Mode Z When performing the leakage diagnosis of EVAP system, the purge control solenoid valve must operate normally. Therefore, mode Z is used to diagnose the purge control solenoid valve stuck open condition. Note that if a purge control solenoid valve stuck open fault is detected, the EVAP system leakage diagnosis is cancelled. Diagnostic method Purge control solenoid valve functional diagnosis is performed by monitoring the tank pressure in mode Z. • Abnormality Judgment If OK judgment cannot be made, extend Mode Z, and Judge as NG when the following conditions are established after predetermined amount of time. Judgment Value Malfunction Criteria evptez – evptezha evptezini Time of no fuel sloshing with value from Map 6 or more

Threshold Value > 0.9 kPa (6.5 mmHg, 0.3 inHg) ≤ 1.4 kPa (10.7 mmHg, 0.4 inHg) ≥ 40000 ms

DTC P0457

Time Needed for Diagnosis: 0 ms + 3000 ms + 13000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. When judgment for purge control solenoid valve stuck open NG is made, end the evaporative diagnosis. Cancel the evaporative diagnosis when the OK/NG judgment for purge control solenoid valve stuck open cannot be made in Mode Z. • Normality Judgment Judge as OK and change to Mode A when the following conditions are established after 3000 ms has passed since Mode Z started. Judgment Value Malfunction Criteria evptez – evptezha

Threshold Value ≤ 0.4 kPa (3 mmHg, 0.1 inHg)

DTC P0457

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Normal (1)

(2) evptez evptezha

evptezini

(3) 0

(4)

(5) EN-02869

(1) (2)

Mode Z 3000 ms

(3) (4)

Fuel tank pressure 0.4 kPa (3 mmHg, 0.1 inHg)

(5)

OK judgment

evptez – evptezha ≤ 0.4 kPa (3 mmHg, 0.1 inHg) Normal when above is established Time Needed for Diagnosis: 0 ms + 3000 ms

GD(H4DOTC)-122

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Purge control solenoid valve Open Fixation

(1)

(2) (3)

(6) evptez evptezini

(4) 0

(5)

evptezha

(7)

(8)

EN-02870

(1) (2) (3)

Mode Z Extended mode Z 0 ms + 3000 ms + 13000 ms

(4) (5) (6)

Fuel tank pressure 0.9 kPa (6.5 mmHg, 0.3 inHg) 1.4 kPa (10.7 mmHg, 0.4 inHg)

• evptezini ≤ 1.4 kPa (10.7 mmHg, 0.4 inHg) • evptez – evptezha > 0.9 kPa (6.5 mmHg, 0.3 inHg) • No fuel sloshing with value from Map 6 or more lasts for 40000 ms. Judge as abnormal when all are established.

GD(H4DOTC)-123

(7) (8)

40000 ms no fuel sloshing NG judgment

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Leak Diagnosis DTC P0442 Evaporative Emission Control System Leak Detected (Small Leak) P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) • The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. • The diagnosis is divided into the following five phases. Mode A: (Estimated evaporation gas amount) Calculate the tank pressure change amount (P1) when using mode A. After calculating P1, switch to mode B. Mode B: (Negative pressure sealed) Introduce negative pressure in the intake manifold to the tank. Approx. 0 → –1.4 kPa (0 → –10.5 mmHg, 0 → –0.4 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. In this case, if the tank pressure does not reach the target negative pressure, judge that there is a large leakage in the system and terminate the evaporative emission control system diagnosis. Abnormality Judgment Judge as NG (large leakage) when the following conditions are established. Judgment Value Malfunction Criteria Time to reach target negative pressure or Mode B time (Min. pressure value in tank when in mode B) – (Tank pressure when mode B started)

Threshold Value ≥ 10000 ms + 25000 ms

DTC P0457

≥ 10000 ms > –0.3 kPa (–2.5 mmHg, –0.1 inHg)

Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms Mode C: (Check pressure rise) Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.) Change to Mode D when the tank pressure returns to the start level of P2 calculation. Judge immediate OK and change to Mode E when it does not return in spite of spending the specified time. Tank pressure when starting calculation of P2 –1.4 kPa (–10.5 mmHg, –0.4 inHg)

Time for advanced OK judgment 23635 ms

Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 23635 ms Mode D: (Measure amount of negative pressure change) Monitor the tank pressure change amount when using mode D. In this case, the tank pressure increases, (nears barometric pressure) because evaporation occurs. However, if any leakage exists, the pressure increases additionally in proportion to this leakage. The pressure variation of this tank is P2. After calculating P2, perform a small leak diagnosis according to the items below. When Mode D is ended Assign tank variations measured in Mode A and Mode D, P1 and P2, to the formula below, judge small leaks in the system. If the measured judgment value exceeds the threshold value, it is judged to be a malfunction.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Abnormality Judgment Judge as NG when the following conditions are established within the predetermined time. Judge as OK and clear the NG if the following conditions are not established within the predetermined time. Judgment Value Malfunction Criteria P2 – 1.5 – × P1 P2: Tank pressure that changes every 10000 ms in mode D P1: Tank pressure that changes every 10000 ms in mode A

Threshold Value > Value of Map 8

DTC P0442

*1.5 –: Evaporation amount compensation value when below negative pressure (Amount of evaporation occurrence increases as a vacuum condition increases.)

Map 8 Fault criteria limit for Evaporative emission control system diagnosis Fuel temperature vs. Fuel level 10.5 2 (2.77 US gal, 2.31 Imp gal) 27 2 (7.13 US gal, 5.94 Imp gal) 43 2 (11.36 US gal, 9.46 Imp gal) 59.5 2 (15.72 US gal, 13.09 Imp gal)

15 °C (59 °F) 0.3 kPa (2.00 mmHg, 0.1 inHg) 0.3 kPa (2.12 mmHg, 0.1 inHg) 0.4 kPa (2.74 mmHg, 0.1 inHg) 0.5 kPa (3.38 mmHg, 0.1 inHg)

25 °C (77 °F) 0.3 kPa (2.17 mmHg, 0.1 inHg) 0.3 kPa (2.22 mmHg, 0.1 inHg) 0.4 kPa (2.91 mmHg, 0.1 inHg) 0.5 kPa (3.86 mmHg, 0.2 inHg)

35 °C (95 °F) 0.3 kPa (2.34 mmHg, 0.1 inHg) 0.3 kPa (2.40 mmHg, 0.1 inHg) 0.4 kPa (3.08 mmHg, 0.1 inHg) 0.5 kPa (3.87 mmHg, 0.2 inHg)

45 °C (113 °F) 0.4 kPa (2.66 mmHg, 0.1 inHg) 0.4 kPa (3.07 mmHg, 0.1 inHg) 0.4 kPa (3.26 mmHg, 0.1 inHg) 0.5 kPa (4.07 mmHg, 0.2 inHg)

Time Needed for Diagnosis: 0 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 23635 ms + 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Leak Diagnosis DTC P0456 Evaporative Emission Control System Leak Detected (very small leak) • The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. • The diagnosis is divided into the following five phases. Mode A: (0 point compensation) When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg). Shift to mode B when returned to the 0 point. Cancel the diagnosis when 0 point does not return in the specified time. Mode B: (Negative pressure introduced) Introduce negative pressure in the intake manifold to the tank. Approx. 0 → –2 kPa (0 → –15 mmHg, 0 → –0.6 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. When the tank internal pressure does not reach the target vacuum pressure, the diagnosis is cancelled. Mode C: (Negative pressure maintained) Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.) Change to Mode D either when the tank pressure returns to the start level of P2 calculation, or when the predetermined amount of time has passed. Mode D: (Calculate the amount of negative pressure change) Monitor the tank pressure in mode D, calculate (P2) the pressure change in the tank, and measure the time (evpdset) for the tank pressure to change to the Mode E shifting pressure. When the Mode E shifting pressure is reached, Mode E is entered. If it does not change to the Mode E shifting pressure after the predetermined amount of time has passed, make advanced OK judgment or cancel the diagnosis.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Normality Judgment Judge as OK when the following conditions are established. Judgment Value Malfunction Criteria Advanced OK judgment 1 Mode D time Tank internal pressure Advanced OK judgment 2 Mode D time P2

Threshold Value ≥ 0 ms + 20000 ms ≤ Value of Map 9 ≥ 0 ms + Value of Map 10 ≤ Value of Map 11

Map 9 Fuel level (2, US gal, Imp gal) Tank pressure (kPa, mmHg, inHgl)

10, 2.64, 2.2 –1.9, –14.61, –0.6

27, 7.13, 5.94 –1.9, –14.61, –0.6

43, 11.36, 9.46 –1.8, –13.64, –0.5

59.5, 15.72, 13.09 –1.8, –13.13, –0.5

Map 10 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

10, 2.64, 2.2

20, 5.28, 4.4

30, 7.93, 6.6

40, 10.57, 8.8

50, 13.21, 11

200000

200000

200000

200000

200000

60, 15.85, 13.2 200000

Map 11 Fuel level (2, US gal, Imp gal) Tank pressure (kPa, mmHg, inHgl)

10, 2.64, 2.2 1.1, 8.52, 0.3

27, 7.13, 5.94 1.1, 8.52, 0.3

43, 11.36, 9.46 1.3, 10, 0.4

59.5, 15.72, 13.09 1.3, 10, 0.4

Mode E: (Evaporation occurrence amount calculation) Calculate the change of tank pressure with the time evpdset (P1) to judge as NG/OK according to the value of P1. (ambiguous determination acceptable). • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria P1

Threshold Value < Value of Map 12

Map 12 Malfunction criteria limit for evaporation diagnosis Time (evpdset) vs Fuel level 10.5 2 (2.77 US gal, 2.31 Imp gal) 27 2 (7.13 US gal, 5.94 Imp gal) 43 2 (11.36 US gal, 9.46 Imp gal) 59.5 2 (15.72 US gal, 13.09 Imp gal)

40000 ms

60000 ms

105000 ms

110000 ms

140000 ms

160000 ms

180000 ms

200000 ms

0 kPa 0.1 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.4 kPa 0.4 kPa 0.4 kPa (0.00 mmHg, (0.70 mmHg, (2.18 mmHg, (2.23 mmHg, (2.53 mmHg, (2.72 mmHg, (2.90 mmHg, (2.90 mmHg, 0 inHg) 0 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0 kPa 0.2 kPa 0.3 kPa 0.3 kPa 0.4 kPa 0.4 kPa 0.4 kPa 0.4 kPa (0.00 mmHg, (1.81 mmHg, (2.46 mmHg, (2.53 mmHg, (2.90 mmHg, (2.90 mmHg, (2.90 mmHg, (2.90 mmHg, 0 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0 kPa 0.2 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0 kPa (0.00 mmHg, (1.53 mmHg, (2.49 mmHg, (2.60 mmHg, (2.60 mmHg, (2.60 mmHg, (2.60 mmHg, (0.00 mmHg, 0 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0 inHg) 0.3 kPa 0.2 kPa 0 kPa 0.3 kPa 0 kPa 0.2 kPa 0.3 kPa 0.3 kPa (0.00 mmHg, (1.31 mmHg, (2.53 mmHg, (2.53 mmHg, (2.53 mmHg, (2.53 mmHg, (1.26 mmHg, (0.00 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0 inHg) 0 inHg) 0 inHg) 0.1 inHg) 0.1 inHg)

Time needed for diagnosis: Value from Map 1 + Value from Map 2 + Value from Map 3 + 0 ms + Value from Map 4 + 0 ms + Value from Map 4 + Value from Map 5 Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Normality Judgment Judge as OK when the following conditions are established. Judgment Value Malfunction Criteria P1

Threshold Value > Value of Map 13

Map 13 Malfunction criteria limit for evaporation diagnosis Time (evpdset) vs Fuel level 10.5 2 (2.77 US gal, 2.31 Imp gal) 27 2 (7.13 US gal, 5.94 Imp gal) 43 2 (11.36 US gal, 9.46 Imp gal) 59.5 2 (15.72 US gal, 13.09 Imp gal)

20000 ms

60000 ms

105000 ms

110000 ms

140000 ms

160000 ms

180000 ms

200000 ms

0 kPa 0.3 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.6 kPa 0.6 kPa 0.6 kPa (0.00 mmHg, (2.20 mmHg, (3.68 mmHg, (3.73 mmHg, (4.03 mmHg, (4.22 mmHg, (4.40 mmHg, (4.40 mmHg, 0 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.6 kPa 0.6 kPa 0.6 kPa 0.6 kPa 0 kPa 0.4 kPa 0.5 kPa 0.5 kPa (0.00 mmHg, (3.31 mmHg, (3.96 mmHg, (4.03 mmHg, (4.40 mmHg, (4.40 mmHg, (4.40 mmHg, (4.40 mmHg, 0.1 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0 inHg) 0 kPa 0.4 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.2 kPa (0.00 mmHg, (3.03 mmHg, (3.99 mmHg, (4.10 mmHg, (4.10 mmHg, (4.10 mmHg, (4.10 mmHg, (1.50 mmHg, 0 inHg) 0.1 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.1 inHg) 0.5 kPa 0.5 kPa 0.5 kPa 0.4 kPa 0.2 kPa 0 kPa 0.4 kPa 0.5 kPa (0.00 mmHg, (2.81 mmHg, (4.03 mmHg, (4.03 mmHg, (4.03 mmHg, (4.03 mmHg, (2.76 mmHg, (1.50 mmHg, 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.1 inHg) 0.1 inHg) 0 inHg) 0.1 inHg) 0.2 inHg)

Time needed for diagnosis: Value from Map 1 + Value from Map 2 + Value from Map 3 + 0 ms + Value from Map 4 + 0 ms + Value from Map 4 + Value from Map 5

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BL:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the drain valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (19)

(14)

(9)

(10)

(15)

(11)

(16)

(12)

(8)

(13)

(17)

(7)

(4)

(2)

(5)

(19)

(6)

(1)

(18)

(3) EN-02294

(1) (2) (3) (4) (5) (6) (7)

Bobbin Coil Diode Stator core End plate Body Yoke

(8) (9) (10) (11) (12) (13) (14)

Magnetic plate Shaft Plate Valve Housing Filter Retainer

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(15) (16) (17) (18) (19)

Diaphragm Movable core Spring Cover O-ring

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal

Threshold Value ≥ 10.9 V ≥ 1 second Low

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal

Threshold Value ≥ 10.9 V ≥ 1 second High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BM:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the drain valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (19)

(14)

(9)

(10)

(15)

(11)

(16)

(12)

(8)

(13)

(17)

(7)

(4)

(2)

(5)

(19)

(6)

(1)

(18)

(3) EN-02294

(1) (2) (3) (4) (5) (6) (7)

Bobbin Coil Diode Stator core End plate Body Yoke

(8) (9) (10) (11) (12) (13) (14)

Magnetic plate Shaft Plate Valve Housing Filter Retainer

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(15) (16) (17) (18) (19)

Diaphragm Movable core Spring Cover O-ring

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal

Threshold Value ≥ 10.9 V ≥ 1 second High

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal

Threshold Value ≥ 10.9 V ≥ 1 second Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BN:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR 1. OUTLINE OF DIAGNOSIS Detect the tank pressure sensor output property abnormality. Judge as NG when there is no pressure variation, which should exist in the tank, considering the engine status.

2. COMPONENT DESCRIPTION

(A) (1)

(2)

(B) (C)

EN-04462

(A)

Output voltage

(B)

Input voltage

(1)

Connector

(2)

Terminals

(C)

To fuel tank

3. ENABLE CONDITION Secondary Parameters Elapsed time after starting the engine Fuel level Fuel temperature Battery voltage Atmospheric pressure

Enable Conditions ≥ 60 s ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) < 35 °C (95 °F) ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg)

4. GENERAL DRIVING CYCLE • Perform the diagnosis continuously after 60 s have passed since the engine started. • Pay attention to the fuel level and temperature.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Number of times that the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is 2 2 (0.53 US gal, 0.44 Imp gal) or more (with enable condition established) Maximum – Minimum tank pressure (with enable condition completed) Maximum – Minimum fuel temperature (with enable condition completed)

Threshold Value ≥ 16 time(s)

< 0 kPa (0.375 mmHg, 0 inHg) ≥ 7 °C (44.6 °F)

If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is less than 2 2 (0.53 US gal, 0.44 Imp gal), extend 60 s and make judgment with the Max. and Min. values for the fuel level in 60 s × 2. If there is no difference after the extension of 60 s, continue further to 60 s × 3, 60 s × 4, 60 s × 5. If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is 2 2 (0.53 US gal, 0.44 Imp gal) or more, the diagnosis counter counts up. Time Needed for Diagnosis: 60 s × 16 time(s) or more Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Maximum — Minimum tank pressure

Threshold Value ≥ 0 kPa (0.375 mmHg, 0 inHg)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BO:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the fuel tank pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A) (1)

(2)

(B) (C)

EN-04462

(A)

Output voltage

(B)

Input voltage

(1)

Connector

(2)

Terminals

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(C)

To fuel tank

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Fuel tank pressure Battery voltage

Threshold Value < –7.4 kPa (–55.6 mmHg, –2.2 inHg) ≥ 10.9 V

Time Needed for Diagnosis: 15000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Fuel tank pressure Battery voltage

Threshold Value ≥ –7.4 kPa (–55.6 mmHg, –2.2 inHg) ≥ 10.9 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BP:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the fuel tank pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A) (1)

(2)

(B) (C)

EN-04462

(A)

Output voltage

(B)

Input voltage

(1)

Connector

(2)

Terminals

(C)

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Vehicle speed All conditions of EVAP canister purge Learning value of evaporation gas concentration (left and right) Main feedback compensation coefficient (left and right) Battery voltage

Enable Conditions ≥ 5000 ms ≥ 2 km/h (1.2 MPH) Complete < 0.08 ≥ 0.9 ≥ 10.9 V

4. GENERAL DRIVING CYCLE Perform the diagnosis when purging enable conditions are met without idling.

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To fuel tank

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Fuel tank pressure Fuel temperature Atmospheric pressure

Threshold Value ≥ 7.9 kPa (59.6 mmHg, 2.3 inHg) < 35 °C (95 °F) ≥ 75 kPa (563 mmHg, 22.2 inHg)

Time Needed for Diagnosis: 15000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Fuel tank pressure

Threshold Value < 7.9 kPa (59.6 mmHg, 2.3 inHg)

Time Needed for Diagnosis: Less than 1 second

BQ:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0442.

BR:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0442.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BS:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the purge control solenoid valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (B)

(A)

EN-02197

(A)

To canister

(B)

To intake manifold

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 1 second

4. GENERAL DRIVING CYCLE Always perform the diagnosis after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Duty ratio of “ON” Terminal output voltage

Threshold Value < 0.75 Low

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal output voltage

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BT:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the purge control solenoid valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (B)

(A)

EN-02197

(A)

To canister

(B)

To intake manifold

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 1 second

4. GENERAL DRIVING CYCLE Always perform the diagnosis after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Duty ratio of “ON” Terminal output voltage

Threshold Value ≥ 0.25 High

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal output voltage

Threshold Value Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BU:DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect malfunctions of the fuel level sensor output property. If the fuel level does not vary in a particular driving condition / engine condition where it should, judge as NG.

2. COMPONENT DESCRIPTION

(A)

0

(B)

EN-01734

(A)

Fuel level

(B)

Resistance

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Accumulated amount of intake air Max. – min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine

Threshold Value ≥ 330957 g (11672.85 oz) < 2.6 2 (0.69 US gal, 0.57 Imp gal) ≥ 10.9 V < 4000 rpm ≥ 5000 ms

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Accumulated amount of intake air Max. – min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine

Threshold Value ≥ 330957 g (11672.85 oz) ≥ 2.6 2 (0.69 US gal, 0.57 Imp gal) ≥ 10.9 V < 4000 rpm ≥ 5000 ms

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BV:DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel level sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(5)

(1)

(4)

(2)

(3)

EN-05371

(1) (2)

Engine control module (ECM) Fuel level sensor

(3) (5)

Fuel sub level sensor Body integrated unit

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Detecting circuit

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms < 0.173 V

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms ≥ 0.173 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BW:DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel level sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(5)

(1)

(4)

(2)

(3)

EN-05371

(1) (2)

Engine control module (ECM) Fuel level sensor

(3) (5)

Fuel sub level sensor Body integrated unit

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Detecting circuit

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms ≥ 7.212 V

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms < 7.212 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BX:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT 1. OUTLINE OF DIAGNOSIS Detect the unstable output faults from the fuel level sensor caused by noise. Judge as NG when the max. value and cumulative value of output voltage variation of the fuel level sensor is larger than the threshold value.

2. ENABLE CONDITION Malfunction Criteria Engine speed Elapsed time after starting the engine Battery voltage Idle switch Fuel level

Vehicle speed = 0 km/h (0 MPH)

Threshold Value ≥ 500 rpm ≥ 1 second ≥ 10.9 V ON ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) and < 59.5 2 (15.72 US gal, 13.09 Imp gal) ≥ 10000 ms

3. GENERAL DRIVING CYCLE • Always perform the diagnosis continuously at idle speed. • Pay attention to the fuel level.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. DIAGNOSTIC METHOD Calculate the Max. value (DELFLMAX) and cumulative value (SUMFL) of output voltage variation of fuel level sensor during 12.2 seconds. Judge it normal when both max. and cumulative values are not over the threshold value. Otherwise, when either of them is over the threshold value, the diagnosis counter counts up. Judge as NG if the counter indicated 4 time(s).

Diagnosis condition

(A) Diagnosis timer

Fuel level sensor A/D value

(C) (D)

Amount of Fuel level output voltage variation

Calculate the Max. value (DELFLMAX) and the cumulative value (SUMFL).

5

6

4 3 2 1 Diagnosis counter

0

(B) EN-05569

(A) (D)

12288 ms Normal

(B)

NG at 4 time(s) counts

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(C)

Malfunction

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Integrated times of the condition reaching follows, DELFLMAX or SUMFL At this time, DELFLMAX: Maximum difference of sensor output for 12288 ms SUMFL: Integrated value of the sensor output deviation for12288 ms

Threshold Value ≥ 4 time(s) ≥ Value from Map ≥ 23.8 V

Map Fuel level (2, US gal, Imp gal) Measured voltage (V)

10, 2.64, 2.2 0.248

20, 5.28, 4.4 0.519

25, 6.61, 5.5 0.796

30, 7.93, 6.6 0.6

43, 11.36, 9.46 1.025

45, 11.89, 9.9 1.069

50, 13.21, 11 1.402

The diagnosis counter does not count up when the following conditions are completed within 12288 ms. Maximum value – minimum value of change of tank pressure during 12288 ms Maximum value – minimum value of battery voltage during 12288 ms

≥ 0 kPa (0.375 mmHg, 0 inHg) ≥ 0.969 V

Time Needed for Diagnosis: 12288 ms × 4 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Threshold Value DELFLMAX < Value from Map SUMFL < 23.8 V At this time, DELFLMAX: Maximum difference of sensor output for 12288 ms SUMFL: Integrated value of the sensor output deviation for12288 ms

Time Needed for Diagnosis: 12288 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BY:DTC P0500 VEHICLE SPEED SENSOR “A” 1. OUTLINE OF DIAGNOSIS Judge as NG when outside of the judgment value. Judge NG when the received data from VDCCM&H/U is abnormal vehicle speed, and the vehicle speed data is impossible.

2. COMPONENT DESCRIPTION Vehicle speed signals are taken in to the VDC control module and hydraulic control unit, and normal/erroneous data of the ABS wheel speed sensor is received by CAN communication from the VDC control module and hydraulic control unit.

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 2000 ms

4. GENERAL DRIVING CYCLE Always perform diagnosis more than 2000 ms after starting the engine.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Front ABS wheel speed sensor status Either of the following is established Front left wheel speed Front right wheel speed

Threshold Value Malfunction ≥ 300 km/h (186.4 MPH) ≥ 300 km/h (186.4 MPH)

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Front left wheel speed

Front right wheel speed

Threshold Value > 0 km/h (0 MPH) and < 300 km/h (186.4 MPH) > 0 km/h (0 MPH) and < 300 km/h (186.4 MPH)

Time Needed for Diagnosis: 2500 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BZ:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED 1. OUTLINE OF DIAGNOSIS Detect the malfunction that actual engine speed is not close to target engine speed during idling. Judge as NG when actual engine speed is not close to target engine speed during idling.

2. ENABLE CONDITION Secondary Parameters Engine coolant temperature Battery voltage Atmospheric pressure Fuel level Elapsed time after starting the engine Feedback of ISC Lambda value (left and right)

After switching air conditioner to ON/ OFF After intake manifold pressure changes by 4 kPa (30 mmHg, 1.2 inHg) or more. Elapsed time after switching neutral position switch to ON/OFF Vehicle speed

Enable Conditions ≥ 72 °C (161.6 °F) ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) ≥ 10.49 s In operation ≥ 0.9 and < 1.1 ≥ 5.1 s > 5.1 s > 5.1 s 0 km/h (0 MPH)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling after warming up engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Actual engine speed — Targeted engine speed Feedback compensation for ISC

Threshold Value < –100 rpm Max.

Time Needed for Diagnosis: 10 s × 3 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Actual engine speed — Targeted engine speed

Threshold Value ≥ –100 rpm

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CA:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED 1. OUTLINE OF DIAGNOSIS Detect the malfunction that actual engine speed is not close to target engine speed during idling. Judge as NG when actual engine speed is not close to target engine speed during idling.

2. ENABLE CONDITION Secondary Parameters Engine coolant temperature Battery voltage Atmospheric pressure Fuel level Elapsed time after starting the engine Feedback of ISC Lambda value (left and right)

After switching air conditioner to ON/ OFF After intake manifold pressure changes by 4 kPa (30 mmHg, 1.2 inHg) or more. Elapsed time after switching neutral position switch to ON/OFF Vehicle speed

Enable Conditions ≥ 72 °C (161.6 °F) ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) ≥ 10.49 s In operation ≥ 0.9 and < 1.1 ≥ 5.1 s > 5.1 s > 5.1 s 0 km/h (0 MPH)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling after warming up engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Actual – Target engine speed Feedback compensation for ISC

Threshold Value ≥ 200 rpm Min.

Time Needed for Diagnosis: 10 s × 3 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Actual – Target engine speed

Threshold Value < 200 rpm

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CB:DTC P0512 STARTER REQUEST CIRCUIT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of starter SW. Judge as ON NG when the starter SW signal remains ON.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Engine condition Starter OFF signal Battery voltage

Threshold Value After engine starting Not detected ≥8V

Time Needed for Diagnosis: 180000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Starter OFF signal Battery voltage

Threshold Value Detected ≥8V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CC:DTC P0513 INCORRECT IMMOBILIZER KEY 1. OUTLINE OF DIAGNOSIS DTC

Item

P0513

Incorrect Immobilizer Key

P1570 P1571

Antenna Reference Code Incompatibility

P1572

IMM Circuit Failure (Except Antenna Circuit)

P1574

Key Communication Failure

P1576 P1577

EGI Control Module EEPROM IMM Control Module EEPROM

P1578

Meter Failure

Outline of Diagnosis Incorrect immobilizer key (Use of unregistered key in body integrated unit) Faulty antenna Reference code incompatibility between body integrated unit and ECM Communication failure between body integrated unit and ECM Failure of body integrated unit to verify key (transponder) ID code or transponder failure ECM malfunctioning Body integrated unit malfunctioning Reference code incompatibility between body integrated unit and combination meter

2. ENABLE CONDITION When starting the engine.

3. GENERAL DRIVING CYCLE Perform the diagnosis only after starting the engine.

4. DIAGNOSTIC METHOD Judge as NG when the conditions for the outline of the diagnosis of the top are established.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CD:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR 1. OUTLINE OF DIAGNOSIS Detect the malfunction of microcomputer (RAM). When there is a problem in the main CPU normal RAM, or the sub CPU normal RAM, judge as NG. Judge as OK when both are operating properly. If it is possible to write data to the whole area of RAM in the initial routine, and is possible to read the same data, it is judged as OK, and if not, NG.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

Diagnosis with the initial routine.

3. GENERAL DRIVING CYCLE Perform the diagnosis as soon as the ignition switch is turned to ON.

4. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Write the specified value to RAM and then read.

Threshold Value The written value cannot be read.

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Write the specified value to RAM and then read.

Threshold Value The written value can be read.

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CE:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR 1. OUTLINE OF DIAGNOSIS Judge as NG when SUM value of ROM is outside the standard value.

2. ENABLE CONDITION Secondary Parameters Ignition switch

Enable Conditions ON

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD Abnormality Judgment Judge as NG if the criteria below are met. Judgment Value Malfunction Criteria SUM value of ROM

Threshold Value Standard

Time Needed for Diagnosis: Undetermined Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CF:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Judge as NG when any one of the followings is established. (1) Monitoring IC operates abnormally. (Monitoring IC malfunction) (2) Input amplifier circuit of throttle position sensor 1 operates abnormally. (fourfold amplifier malfunction) (3) CPU operates abnormally. (Instruction/flow check) (4) A/D converter operates abnormally. (ADC malfunction) (5) EEPROM operates abnormally. (EEPROM malfunction) (6) Output IC operates abnormally. (Output driver malfunction)

2. COMPONENT DESCRIPTION

(1)

(9)

(8)

(12)

(7)

(10) (7)

(2)

(3)

(4)

(7) (13)

(5)

(11)

(7)

(6)

EN-08016

(1)

Throttle position sensor

(6)

(2) (3) (4) (5)

Throttle position sensor 1 Throttle position sensor 2 Accelerator pedal position sensor Accelerator pedal position sensor 1

(7) (8) (9)

Accelerator pedal position sensor 2 I/F circuit Amplifier circuit Engine control module (ECM)

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(10)

CPU

(11) (12) (13)

Monitoring IC EEPROM Output IC

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters (1) Battery voltage (2) Ignition switch (2) Battery voltage (3) Ignition switch (3) ETC control (4) Ignition switch (4) Battery voltage (5) Starter switch (5) Battery voltage (6) Ignition switch (6) Battery voltage

Enable Conditions ≥6V ON ≥6V ON Permitted ON ≥6V OFF >6V ON ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria (1) Monitoring IC operation

Threshold Value The result and estimated value match. 1: Lean λ < 1: Rich

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1)

Atmosphere

(3)

ZrO2

(4)

Ceramic heater

(2)

Exhaust gas

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Atmospheric pressure Rear oxygen sensor sub feedback Rear oxygen sensor output voltage – Feedback target voltage or rear oxygen sensor sub feedback compensation coefficient or rear oxygen sensor sub feedback compensation coefficient Elapsed time after starting the engine Engine coolant temperature Vehicle speed Amount of intake air Load change at 180° CA Front oxygen (A/F) sensor impedance Learning value of evaporation gas density Total time of operating canister purge Targeted lambda value load compensation coefficient

Enable Conditions ≥ 4096 ms ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) Execution –0.2 V — 0.1 V On Min. On Max. ≥ 60000 ms ≥ 72 °C (161.6 °F) ≥ 20 km/h (12.4 MPH) ≥ 6 g/s (0.21 oz/s) < 0.02 g/rev (0 oz/rev) 0 Ω — 50 Ω < 0.2 ≥ 19.9 s –1 — 1

4. GENERAL DRIVING CYCLE Perform diagnosis continuously at a constant speed of 20 km/h (12.4 MPH) or more after 60000 ms have passed since the engine started.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria λ value

Threshold Value < 0.85

Time Needed for Diagnosis: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria λ value

Threshold Value ≥ 0.85

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CK:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1) 1. OUTLINE OF DIAGNOSIS Detect that λ value remains high. Judge as NG when lambda value is abnormal in accordance with λ value of front oxygen (A/F) sensor and running conditions such as vehicle speed, amount of intake air, engine coolant temperature, sub feedback control, etc. λ value = Actual air fuel ratio/Theoretical air fuel ratio λ > 1: Lean λ < 1: Rich

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1)

Atmosphere

(3)

ZrO2

(4)

Ceramic heater

(2)

Exhaust gas

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Atmospheric pressure Rear oxygen sensor sub feedback Rear oxygen sensor output voltage – Feedback target voltage or rear oxygen sensor sub feedback compensation coefficient or rear oxygen sensor sub feedback compensation coefficient Elapsed time after starting the engine Engine coolant temperature Vehicle speed Amount of intake air Load change at 180° CA Front oxygen (A/F) sensor impedance Learning value of evaporation gas density Total time of operating canister purge Targeted lambda value load compensation coefficient

Enable Conditions ≥ 4096 ms ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) Execution –0.2 V — 0.1 V On Min. On Max. ≥ 60000 ms ≥ 72 °C (161.6 °F) ≥ 20 km/h (12.4 MPH) ≥ 6 g/s (0.21 oz/s) < 0.02 g/rev (0 oz/rev) 0 Ω — 50 Ω < 0.2 ≥ 19.9 s –1 — 1

4. GENERAL DRIVING CYCLE Perform diagnosis continuously at a constant speed of 20 km/h (12.4 MPH) or more after 60000 ms have passed since the engine started.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria λ value

Threshold Value > 1.15

Time Needed for Diagnosis: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria λ value

Threshold Value ≤ 1.15

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CL:DTC P1160 RETURN SPRING FAILURE 1. OUTLINE OF DIAGNOSIS Judge as NG when the valve is opened more than the default opening angle, but does not move to the close direction with the motor power stopped.

2. COMPONENT DESCRIPTION

(1)

(8)

(3)

(2)

S S (7) (6) (4)

(5)

EN-04463

(1) (2)

Opener spring Return spring

(4) (5)

Full closed stopper Throttle valve

(3)

Intermediate stopper

(6)

Gear

3. ENABLE CONDITION Secondary Parameters Battery voltage Throttle position sensor

Enable Conditions ≥6V Normal

4. GENERAL DRIVING CYCLE • Ignition switch ON → OFF • Ignition switch OFF → ON (Only after clearing memory)

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(7) (8)

DC motor Main and sub throttle position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Opening variation after continuity is set to OFF

Threshold Value –4 kPa (–30 mmHg, –1.2 inHg) ≥ 30000 ms Not = 0 –10 °C (14 °F) — 55 °C (131 °F) ≥ –26.7 kPa (–200 mmHg, –7.9 inHg)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CP:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of starter SW. Judge as OFF NG when it becomes after engine start despite no starter ON experience.

2. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment Judge as OFF NG when the following conditions are established. Judgment Value Malfunction Criteria Vehicle speed Starter ON signal Engine condition Battery voltage

Threshold Value < 1 km/h (0.6 MPH) Not detected Changed from before start to after start ≥8V

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OFF OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Starter ON Starter ON diagnosis Battery voltage

Threshold Value Experienced No diagnosis experience ≥8V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CQ:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION 1. OUTLINE OF DIAGNOSIS Detect the open/short circuit of back-up power supply circuit. Judge as NG when the backup power voltage is low.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Voltage of back-up power supply Battery voltage Engine condition

Threshold Value Low ≥ 10.9 V After engine starting

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Voltage of back-up power supply Battery voltage Engine condition

Threshold Value High ≥ 10.9 V After engine starting

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CR:DTC P1570 ANTENNA 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

CS:DTC P1571 REFERENCE CODE INCOMPATIBILITY 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

CT:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

CU:DTC P1574 KEY COMMUNICATION FAILURE 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

CV:DTC P1576 EGI CONTROL MODULE EEPROM 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

CW:DTC P1577 IMM CONTROL MODULE EEPROM 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

CX:DTC P1578 METER FAILURE 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CY:DTC P1602 CONTROL MODULE PROGRAMMING ERROR 1. OUTLINE OF DIAGNOSIS Detect malfunctions of the catalyst advanced idling retard angle control. Judge as NG when ECM is not controlling the angle properly during catalyst advanced idling retard angle control. Judge as NG if there is exhaust gas temperature diagnosis, idle speed diagnosis and final ignition timing diagnosis, and if any one of them is NG. • Exhaust temperature diagnosis Judge as NG when the estimated exhausted gas temperature in 14 seconds after the cold start is below the specified value. • Idle speed diagnosis Judge as NG when actual engine speed is not close to target engine speed after terminating the retard angle control. • Final ignition timing diagnosis Judge as NG when actual retard amount is under the specified value at cold start.

2. ENABLE CONDITION Secondary Parameters Atmospheric pressure Battery voltage Cold start diagnosis Vehicle speed Misfire in 200 engine revs. Elapsed time after starting the engine

Enable Conditions ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 10.9 V Incomplete < 3 km/h (1.9 MPH) –200 rpm) Continuous time of (actual retard amount > 30 °CA)

Threshold Value ≥ 6000 ms ≥ 0 ms

Time Needed for Diagnosis: 14 seconds Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Continuous time of (Target engine speed – Actual engine speed > –200 rpm) Continuous time of (actual retard amount > 30 °CA)

Threshold Value < 6000 ms < 0 ms

Time Needed for Diagnosis: Less than 1 second • Final ignition timing diagnosis Abnormality Judgment Judge as NG when the following conditions are established with diagnosis enable conditions successful. Judgment Value Malfunction Criteria Duration time of (Standard ignition timing – Actual ignition timing ≤ 0 °CA)

Threshold Value > 5000 ms

Time Needed for Diagnosis: 5000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Continuous time of (Standard ignition timing – Actual ignition timing > 0 °CA)

Threshold Value > 5000 ms

Time Needed for Diagnosis: 5000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CZ:DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of tumble generator valve motor function. Judge open fixing malfunction when the opening degree is large even after finishing the tumble generator valve closing driving.

2. ENABLE CONDITION Secondary Parameters Battery voltage Engine coolant temperature Ambient air temperature

Enable Conditions ≥ 10.9 V ≥ –30 °C (–22 °F) ≥ –30 °C (–22 °F)

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Tumble generator valve opening Tumble generator valve “close” signal output

Threshold Value ≥ 64.3 ° ≥ 3200 ms

Time Needed for Diagnosis: 3000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Tumble generator valve opening Tumble generator valve “close” signal output

Threshold Value < 64.3 ° ≥ 3200 ms

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DA:DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of tumble generator valve motor function. Judge open fixing malfunction when the opening degree is large even after finishing the tumble generator valve closing driving.

2. ENABLE CONDITION Secondary Parameters Battery voltage Engine coolant temperature Ambient air temperature

Enable Conditions ≥ 10.9 V ≥ –30 °C (–22 °F) ≥ –30 °C (–22 °F)

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Tumble generator valve opening Tumble generator valve “close” signal output

Threshold Value ≥ 64.3 ° ≥ 3200 ms

Time Needed for Diagnosis: 3000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Tumble generator valve opening Tumble generator valve “close” signal output

Threshold Value < 64.3 ° ≥ 3200 ms

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DB:DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of tumble generator valve motor function. Judge close fixing malfunction when the opening degree is small even after finishing the tumble generator valve open driving.

2. ENABLE CONDITION Secondary Parameters Battery voltage Engine coolant temperature Ambient air temperature

Enable Conditions ≥ 10.9 V ≥ –30 °C (–22 °F) ≥ –30 °C (–22 °F)

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Tumble generator valve opening Tumble generator valve “open” signal output

Threshold Value < 64.3 ° ≥ 4600 ms

Time Needed for Diagnosis: 3000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Tumble generator valve opening Tumble generator valve “open” signal output

Threshold Value ≥ 64.3 ° ≥ 4600 ms

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DC:DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of tumble generator valve motor function. Judge close fixing malfunction when the opening degree is small even after finishing the tumble generator valve open driving.

2. ENABLE CONDITION Secondary Parameters Battery voltage Engine coolant temperature Ambient air temperature

Enable Conditions ≥ 10.9 V ≥ –30 °C (–22 °F) ≥ –30 °C (–22 °F)

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Tumble generator valve opening Tumble generator valve “open” signal output

Threshold Value < 64.3 ° ≥ 4600 ms

Time Needed for Diagnosis: 3000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Tumble generator valve opening Tumble generator valve “open” signal output

Threshold Value ≥ 64.3 ° ≥ 4600 ms

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DD:DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of tumble generator valve motor. Judge as NG when the open signal is sent from IC after tumble generator valve driving IC diagnosis.

2. COMPONENT DESCRIPTION (1)

(3)

M

(2)

E

E EN-01789

(1)

Engine control module (ECM)

(2)

Tumble generator valve

(3)

Battery

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment At the main IC, check the sent signal at each timing which occurs immediately after the tumble generator valve output is set to ON → OFF, and judge open NG when the open NG signal is sent 96 ms × 20 time(s) in a row. Judgment Value Malfunction Criteria Open NG signal input

Threshold Value Low

Time Needed for Diagnosis: 96 ms × 20 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG when the OK signal is sent. Judgment Value Malfunction Criteria Open NG signal input

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DE:DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of tumble generator valve motor. Judge as NG when the overcurrent signal is sent from IC after tumble generator valve driving IC diagnosis.

2. COMPONENT DESCRIPTION (1)

(3)

M

(2)

E

E EN-01789

(1)

Engine control module (ECM)

(2)

Tumble generator valve

(3)

Battery

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON → OFF, and judge open NG when the open NG signal is sent 96 ms × 10 time(s) in a row. Judgment Value Malfunction Criteria Overcurrent NG signal input

Threshold Value Low

Time Needed for Diagnosis: 96 ms × 10 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG when the OK signal is sent. Judgment Value Malfunction Criteria Overcurrent NG signal input

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DF:DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of tumble generator valve motor. Judge as NG when the open signal is sent from IC after tumble generator valve driving IC diagnosis.

2. COMPONENT DESCRIPTION (1)

(3)

M

(2)

E

E EN-01789

(1)

Engine control module (ECM)

(2)

Tumble generator valve

(3)

Battery

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON → OFF, and judge open NG when the open NG signal is sent 96 ms × 20 time(s) in a row. Judgment Value Malfunction Criteria Open NG signal input

Threshold Value Low

Time Needed for Diagnosis: 96 ms × 20 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG when the OK signal is sent. Judgment Value Malfunction Criteria Open NG signal input

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DG:DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of tumble generator valve motor. Judge as NG when the overcurrent signal is sent from IC after tumble generator valve driving IC diagnosis.

2. COMPONENT DESCRIPTION (1)

(3)

M

(2)

E

E EN-01789

(1)

Engine control module (ECM)

(2)

Tumble generator valve

(3)

Battery

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON → OFF, and judge open NG when the open NG signal is sent 96 ms × 10 time(s) in a row. Judgment Value Malfunction Criteria Overcurrent NG signal input

Threshold Value Low

Time Needed for Diagnosis: 96 ms × 10 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG when the OK signal is sent. Judgment Value Malfunction Criteria Overcurrent NG signal input

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DH:DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of tumble generator valve position sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(3)

(4) (1)

(2)

EN-01768

(1)

Rotor

(2)

Return spring

(3)

Voltage (V)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Tumble generator valve opening (°)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.217 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.217 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DI: DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of tumble generator valve position sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(3)

(4) (1)

(2)

EN-01768

(1) (2)

Rotor Return spring

(3)

Voltage (V)

(4)

Throttle valve opening angle (°)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.783 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.783 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DJ:DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of tumble generator valve position sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(3)

(4) (1)

(2)

EN-01768

(1)

Rotor

(2)

Return spring

(3)

Voltage (V)

(4)

Tumble generator valve opening (°)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.217 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.217 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DK:DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of tumble generator valve position sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(3)

(4) (1)

(2)

EN-01768

(1)

Rotor

(2)

Return spring

(3)

Voltage (V)

(4)

Tumble generator valve opening (°)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.783 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.783 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DL:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the oil flow control solenoid valve. Judge as NG when the current is small even though the duty signal is large.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current

Threshold Value ≥ 10.9 V ≥ 99.61 % < 0.306 A

Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Target current value of the oil flow control solenoid valve |Target current value of the oil flow control solenoid valve – oil flow control solenoid valve control current value|

Threshold Value ≥ 10.9 V ≥ 0.14 A < 0.08 A

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DM:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of oil flow control solenoid valve. Judge as NG when the current is large even though the duty signal is small.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current

Threshold Value ≥ 10.9 V < 0.39 % ≥ 0.306 A

Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage |Target current value of the oil flow control solenoid valve – oil flow control solenoid valve control current value|

Threshold Value ≥ 10.9 V < 0.08 A

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DN:DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the oil flow control solenoid valve. Judge as NG when the current is small even though the duty signal is large.

2. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current

Threshold Value ≥ 10.9 V ≥ 99.61 % < 0.306 A

Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Target current value of the oil flow control solenoid valve |Target current value of the oil flow control solenoid valve – oil flow control solenoid valve control current value|

Threshold Value ≥ 10.9 V ≥ 0.14 A < 0.08 A

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DO:DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of oil flow control solenoid valve. Judge as NG when the current is large even though the duty signal is small.

2. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current

Threshold Value ≥ 10.9 V < 0.39 % ≥ 0.306 A

Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage |Target current value of the oil flow control solenoid valve – oil flow control solenoid valve control current value|

Threshold Value ≥ 10.9 V < 0.08 A

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DP:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P2088.

DQ:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P2089.

DR:DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P2090.

DS:DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P2091.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DT:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of fuel system from the size of the sub feedback learning value. Control the sub feedback learning and judge as NG when the learning value is in the lean zone.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

3. ENABLE CONDITION Secondary Parameters Conditions for carrying out the sub feedback learning Continuous time when all conditions are established.

Enable Conditions Complete ≥1s

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km/h (50 MPH) or more.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sub feedback learning value

Threshold Value < –0.05

Time Needed for Diagnosis: 5 s × 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sub feedback learning value

Threshold Value ≥ –0.05 + 0

Time Needed for Diagnosis: 5 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DU:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of fuel system from the size of the sub feedback learning value. Sub feedback learning is being performed. When the learning value goes to the rich side, judge as NG.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

3. ENABLE CONDITION Secondary Parameters Conditions for carrying out the sub feedback learning Continuous time when all conditions are established.

Enable Conditions Complete ≥1s

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km/h (50 MPH) or more.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sub feedback learning value

Threshold Value ≥ 0.03

Time Needed for Diagnosis: 5 s × 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sub feedback learning value

Threshold Value < 0.03 + 0

Time Needed for Diagnosis: 5 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DV:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE 1. OUTLINE OF DIAGNOSIS Judge as NG when the motor current becomes large or drive circuit is heated.

2. COMPONENT DESCRIPTION 12V

12V

(1)

(6)

(2)

(3)

(7)

(4)

(2)

(5) EN-01867

(1) (2) (3)

Engine control module (ECM) Detecting circuit Overcurrent detection circuit

(4) (5)

Drive circuit Temperature detection circuit

3. ENABLE CONDITION Secondary Parameters Under control of electronic throttle control CPU communication line sub → main normal judgment

Enable Conditions ON Normal

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(6) (7)

Electronic throttle control relay Motor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Motor current or Drive circuit inner temperature

Threshold Value >8A > 175°C (347°F)

Time Needed for Diagnosis: 512 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Motor current Drive circuit inner temperature

Threshold Value ≤8A ≤ 175°C (347°F)

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DW:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Judge as NG when the electronic throttle control power is not supplied even when ECM sets the electronic throttle control relay to ON.

2. COMPONENT DESCRIPTION 12V

12V

(1)

(4)

(2)

(5)

(3)

EN-01868

(1) (2)

Engine control module (ECM) Voltage detection circuit

(3) (4)

Drive circuit Electronic throttle control relay

3. ENABLE CONDITION Secondary Parameters Battery voltage Electronic throttle control relay output

Enable Conditions ≥ 11 V ON

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Motor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Motor power voltage

Threshold Value ≤5V

Time Needed for Diagnosis: 352 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Motor power voltage

Threshold Value >5V

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DX:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Judge as NG when the electronic throttle control power is supplied even when ECM sets the electronic throttle control relay to OFF.

2. COMPONENT DESCRIPTION 12V

12V

(1)

(4)

(2)

(5)

(3)

EN-01868

(1) (2)

Engine control module (ECM) Voltage detection circuit

(3) (4)

Drive circuit Electronic throttle control relay

3. ENABLE CONDITION Secondary Parameters Battery voltage Electronic throttle control relay output

Enable Conditions ≥6V OFF

4. GENERAL DRIVING CYCLE • When ignition switch ON → OFF • Ignition switch OFF → ON (Only after clearing memory)

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Motor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Motor power voltage

Threshold Value ≥5V

Time Needed for Diagnosis: 600 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Motor power voltage

Threshold Value 20.116 °

or Throttle opening angle when the ignition switch is ON – Throttle minimum stop position

< 0.887 °

Time Needed for Diagnosis: 8 ms — 80 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Throttle sensor opening angle at full close point learning

Threshold Value ≥ 9.884 ° and ≤ 20.116 °

Throttle opening angle when the ignition switch is ON – Throttle minimum stop position

≥ 0.887 °

Time Needed for Diagnosis: 8 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DZ:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value < 0.217 V

Time Needed for Diagnosis: 100 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value ≥ 0.217 V

Time Needed for Diagnosis: 100 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EA:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value ≥ 4.783 V

Time Needed for Diagnosis: 32 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 1 input voltage

Threshold Value < 4.783 V

Time Needed for Diagnosis: 32 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EB:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value < 0.217 V

Time Needed for Diagnosis: 100 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value ≥ 0.217 V

Time Needed for Diagnosis: 100 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EC:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value ≥ 4.783 V

Time Needed for Diagnosis: 100 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Sensor 2 input voltage

Threshold Value < 4.783 V

Time Needed for Diagnosis: 100 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

ED:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION 1. OUTLINE OF DIAGNOSIS Judge as NG when the signal level of throttle position sensor 1 is different from the throttle position sensor 2.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Engine control module (ECM)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the NG range of judgment value detail

Details of Judgment Value

(Y5)

(NG area)

(Y4) Sensor output difference (˚)

(Y3) (Y2) (OK area)

(Y1)

0 0 (X1) (X2)

(X3)

(X4)

Throttle position sensor 1 opening angle (˚)

EN-08032

(X1) (X4)

2.125 ° 31.625 °

(X2)

4.25 °

(X3)



(Y1) (Y4)

5.15 ° 10.4 °

(Y2) (Y5)

6.15 ° 12.4 °

(Y3)

8.28 °

Time Needed for Diagnosis: 212 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the OK range of judgment value detail

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EE:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION 1. OUTLINE OF DIAGNOSIS Judge as NG when the signal level of throttle position sensor 1 is different from the throttle position sensor 2.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the NG range of judgment value detail

Details of Judgment Value

(Y5)

(Y4) Sensor output difference (˚)

(NG area)

(Y3) (Y2) (Y1) (OK area)

0 0

(X1)

(X2)

(X3)

(X4)

Accelerator pedal position sensor 1 opening angle (˚) EN-08033

(X1) (X4)

0.6 ° 4°

(X2)

1.2 °

(X3)



(Y1) (Y4)

1.465 ° 2.455 °

(Y2) (Y5)

1.597 ° 3.116 °

(Y3)

1.663 °

Time Needed for Diagnosis: 116 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the OK range of judgment value detail

Time Needed for Diagnosis: 116 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EF:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect the malfunction of barometric pressure sensor output property. Judge as NG when the barometric pressure sensor output is largely different from the intake manifold pressure at engine start.

2. COMPONENT DESCRIPTION The barometric pressure sensor is built into the ECM.

3. ENABLE CONDITIONS Secondary Parameters Engine speed Vehicle speed

Enable Conditions < 300 rpm < 1 km/h (0.6 MPH)

4. GENERAL DRIVING CYCLE Perform the diagnosis once at ignition switch ON.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria |Barometric pressure – Intake manifold pressure| |Intake manifold pressure at engine start – Intake manifold pressure|

Threshold Value ≥ 26.7 kPa (200 mmHg, 7.9 inHg) < 1.3 kPa (9.99 mmHg, 0.4 inHg)

Time Needed for Diagnosis: 328 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria |Barometric pressure – Intake manifold pressure|

Threshold Value < 26.7 kPa (200 mmHg, 7.9 inHg)

Time Needed for Diagnosis: 262 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EG:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open/short circuit of the barometric pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION The barometric pressure sensor is built into the ECM.

3. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 1.707 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 1.707 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EH:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open/short circuit of the barometric pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION The barometric pressure sensor is built into the ECM.

3. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.234 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.234 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EI: DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the purge control solenoid valve 2. Judge as NG when the ECM output level differs from the actual terminal level.

2. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal

Threshold Value ≥ 10.9 V ≥ 1 second Low

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal

Threshold Value ≥ 10.9 V ≥ 1 second High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EJ:DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the purge control solenoid valve 2. Judge as NG when the ECM output level differs from the actual terminal level.

2. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal

Threshold Value ≥ 10.9 V ≥ 1 second High

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal

Threshold Value ≥ 10.9 V ≥ 1 second Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EK:DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION 1. OUTLINE OF DIAGNOSIS Detect malfunction of CAN communication. When CAN communications is not possible, and CAN communications with TCM, VDC CM and body integrated unit is not possible, judge as NG if data from the TCM, VDC CM and body integrated unit are not normal.

2. COMPONENT DESCRIPTION ECM, TCM, VDC CM and body integrated unit are connected by high speed CAN.

(Common Specifications) CAN Protocol 2.0 B (Active) Frame Format: 11 Bit ID Frame (Standard Frame) (High speed CAN) Conforms to ISO11898 Communication Speed: 500 kbps

3. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting the engine.

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Battery voltage Starter switch Engine bus off flag or error warning flag or ID received from control module connected to driving system CAN or Data updated from control module connected to driving system CAN

Threshold Value > 10.9 V OFF run set (error) None during 500 milliseconds None during 2000 milliseconds

Time Needed for Diagnosis: 2 seconds Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Starter switch Engine bus off flag or error warning flag ID received from control module connected to driving system CAN Data updated from control module connected to driving system CAN

Threshold Value > 10.9 V OFF run clear (No error) Yes Yes

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EL:DTC U0101 CAN (TCU) DATA NOT LOADED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

EM:DTC U0122 CAN (VDC) DATA NOT LOADED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

EN:DTC U0140 CAN (BCU) DATA NOT LOADED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

EO:DTC U0402 CAN (TCU) DATA ABNORMAL 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

EP:DTC U0416 CAN (VDC) DATA ABNORMAL 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

EQ:DTC U0422 CAN (BCU) DATA ABNORMAL 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

GD(H4DOTC)-230

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2010 LEGACY SERVICE MANUAL

QUICK REFERENCE INDEX

ENGINE 3 SECTION

This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of 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.

FUEL INJECTION (FUEL SYSTEMS)

FU(H6DO)

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(H6DO)

INTAKE (INDUCTION)

IN(H6DO)

MECHANICAL

ME(H6DO)

EXHAUST

EX(H6DO)

COOLING

CO(H6DO)

LUBRICATION

LU(H6DO)

SPEED CONTROL SYSTEMS

SP(H6DO)

IGNITION

IG(H6DO)

STARTING/CHARGING SYSTEMS

SC(H6DO)

ENGINE (DIAGNOSTICS)

EN(H6DO) (diag)

GENERAL DESCRIPTION

GD(H6DO)

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD.

G2460BE4

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FUEL INJECTION (FUEL SYSTEMS)

FU(H6DO) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

Page General Description ...................................................................................2 Throttle Body ............................................................................................19 Intake Manifold .........................................................................................21 Engine Coolant Temperature Sensor .......................................................28 Crankshaft Position Sensor ......................................................................30 Camshaft Position Sensor ........................................................................32 Knock Sensor ...........................................................................................34 Throttle Position Sensor ...........................................................................35 Manifold Absolute Pressure Sensor .........................................................36 Mass Air Flow and Intake Air Temperature Sensor .................................38 EGR Valve ...............................................................................................39 Fuel Injector .............................................................................................40 Oil Flow Control Solenoid Valve ...............................................................43 Oil Temperature Sensor ...........................................................................45 Front Oxygen (A/F) Sensor ......................................................................46 Rear Oxygen Sensor ................................................................................48 Engine Control Module (ECM) .................................................................50 Main Relay ...............................................................................................51 Fuel Pump Relay ......................................................................................52 Electronic Throttle Control Relay .............................................................53 Fuel Pump Control Unit ............................................................................54 Fuel ..........................................................................................................55 Fuel Tank .................................................................................................57 Fuel Filler Pipe .........................................................................................64 Fuel Pump ................................................................................................67 Fuel Level Sensor ....................................................................................69 Fuel Sub Level Sensor .............................................................................71 Fuel Filter .................................................................................................73 Fuel Damper ............................................................................................75 Fuel Delivery and Evaporation Lines .......................................................76 Fuel System Trouble in General ..............................................................81

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General Description FUEL INJECTION (FUEL SYSTEMS)

1. General Description A: SPECIFICATION Fuel tank

Fuel pump

Capacity Install locations Type Shutoff discharge pressure Discharge rate

Fuel filter

70 2 (18.5 US gal, 15.4 Imp gal) Rear floor under Impeller 850 kPa (8.67 kg/cm2, 123.3 psi) or less 155 2 (41 US gal, 34.1 Imp gal)/h or more. [12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)] In-tank type

FU(H6DO)-2

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General Description FUEL INJECTION (FUEL SYSTEMS)

B: COMPONENT 1. INTAKE MANIFOLD

T4

T2 (16) T3 (9)

T4

(18)

(17) T5

T2

(7)

(6)

(5)

(15)

T5

T4

(10)

T4 (17) T3

(8)

(3) T4 (1) (2) T2 (11)

(4)

(14)

(2)

(13)

T4

(14)

T2

T1

T2 T2

T2

(14) (13) (14) T2 (12)

T1 FU-04653

FU(H6DO)-3

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General Description FUEL INJECTION (FUEL SYSTEMS) (1) (2) (3) (4) (5) (6) (7) (8) (9)

Intake manifold O-ring Manifold absolute pressure sensor Filter Fuel pipe protector RH Purge control solenoid valve Hose Hose Nipple

(10) (11) (12) (13) (14) (15) (16) (17) (18)

PLUG Fuel pipe protector LH Fuel pipe ASSY Hose Clamp EGR valve Gasket Gasket EGR pipe

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Tightening torque:N·m (kgf-m, ft-lb) T1: 1.25 (0.1, 0.9) T2: 6.4 (0.7, 4.7) T3: 17 (1.7, 12.5) T4: 19 (1.9, 14.0) T5: 25 (2.5, 18.4)

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General Description FUEL INJECTION (FUEL SYSTEMS)

2. FUEL INJECTOR

(12)

T1 (8)

(2)

T1

T3

T2 (8) (3)

(9)

(7)

(8)

T2

(4) T2

(5) (6)

T3

T1 T1 (8)

(10) (9)

(8)

(1)

(11)

(3) (4) (5) (6) FU-04916

(1) (2) (3) (4) (5) (6)

Fuel injector pipe LH Fuel injector pipe RH O-ring Injection rubber Fuel injector Seal ring

(7) (8) (9) (10) (11) (12)

Fuel pipe ASSY Clamp Hose Cylinder head LH Cylinder head RH Intake manifold

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Tightening torque:N·m (kgf-m, ft-lb) T1: 1.25 (0.1, 0.9) T2: 6.4 (0.7, 4.7) T3: 19 (1.9, 14.0)

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General Description FUEL INJECTION (FUEL SYSTEMS)

3. AIR INTAKE SYSTEM T (2)

(1)

FU-04915

(1)

O-ring

(2)

Throttle body

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Tightening torque:N·m (kgf-m, ft-lb) T: 8 (0.8, 5.9)

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General Description FUEL INJECTION (FUEL SYSTEMS)

4. SENSOR T3 T3 T1 (2) (3)

T3

T1 (4) T2

(6) T1

(1)

(13)

T1 (9) (5)

T1 T1 (11) (7)

T2 T1 (10) (8)

(12) T1

(1)

Crankshaft position sensor

(7)

(2) (3)

Knock sensor RH Knock sensor LH

(8) (9)

(4)

Intake camshaft position sensor RH Intake camshaft position sensor LH Intake oil flow control solenoid valve RH

(10)

(5) (6)

(11) (12)

Intake oil flow control solenoid valve LH Oil temperature sensor Exhaust oil flow control solenoid valve RH Exhaust oil flow control solenoid valve LH Exhaust camshaft position sensor RH Exhaust camshaft position sensor LH

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(13)

FU-04652

Engine coolant temperature sensor

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 22 (2.2, 16.2) T3: 25 (2.5, 18.4)

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General Description FUEL INJECTION (FUEL SYSTEMS)

5. ENGINE HARNESS Engine harness assembly diagram 1 (18) 10

(2)

(20)

(19)

1

(1)

11

2 (3)

9

(4)

(17)

3 (16) (5) 3

(A) (6)

(15) (14)

3

3

(7) (13) (12)

(11)

7

4

(10) 6

8 (21)

(9)

5

(8)

(22) 12

(23)

(B)

(25)

14 (24)

13 ME-04534

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General Description FUEL INJECTION (FUEL SYSTEMS) (A)

Cylinder block upper face

(B)

Intake manifold back surface

(1)

Crankshaft position sensor connector Engine ground

(10)

Knock sensor LH connector

(19)

(11)

Power steering switch connector

(20)

(3)

Intake camshaft position sensor LH connector

(12)

Knock sensor RH connector

(21)

(4)

#6 injector connector

(13)

Intake oil flow control solenoid valve RH connector

(22)

(5)

#4 injector connector

(14)

#1 injector connector

(23)

(6)

#2 injector connector

(15)

#3 injector connector

(24)

(7)

Intake oil flow control solenoid valve LH connector Oil temperature sensor connector

(16)

#5 injector connector

(25)

(17)

Intake camshaft position sensor RH connector Engine harness docking connector

(2)

(8) (9)

Engine coolant temperature sensor connector

(18)

Upper/lower connection connector (To intake manifold) Electronic throttle control connector (To intake manifold) Electronic throttle control connector (From upper part of the cylinder block) Upper/lower connection connector (From upper part of the cylinder block) Purge control solenoid valve connector Manifold absolute pressure sensor connector EGR valve connector

*1: Install so that engine ground terminals face the rear side of vehicle. *2: Route under the heater pipe. *3: Attach the engine harness fixing clip to the fuel pipe stay. *4: Route from the cutout portion on the fuel pipe protector LH. *5: Be careful not to mix up the connectors of oil temperature sensor and engine coolant temperature sensor. *6: Route between crankshaft position sensor and knock sensor LH. *7: Route under the heater pipe. *8: Route under the heater pipe. *9: Route under the fuel pipe. *10: Attach the engine harness fixing clip to the fixing boss on the cylinder block. *11: Route over the heater pipe stay. *12: Securely install the engine harness fixing stay. *13: Route outside the fuel pipe. *14: Attach the engine harness fixing clip to the fixing stay on the intake manifold.

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General Description FUEL INJECTION (FUEL SYSTEMS)

Engine harness assembly diagram 2

(B)

(A)

1 1 (11) (6)

(1)

(10) (7)

2

(3) (9)

(8)

(5)

2

(4)

(2)

ME-04149

(A)

Right side of the engine

(B)

Left side of the engine

(1)

#6 ignition coil connector

(5)

(2) (3)

#4 ignition coil connector Exhaust oil flow control valve solenoid LH connector #2 ignition coil connector

(6) (7)

Exhaust camshaft position sensor LH connector #1 injector connector Exhaust camshaft position sensor RH connector Oil pressure switch connector

(4)

(8)

(9) (10) (11)

Exhaust oil flow control valve solenoid RH connector #3 ignition coil connector #5 ignition coil connector

*1: Align the engine harness stay end with the end of engine harness identification tape. *2: Attach the engine harness fixing clip to the fixing boss on the rocker cover.

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General Description FUEL INJECTION (FUEL SYSTEMS)

6. FUEL TANK (23)

T1

(8)

T1 T1

(7) (14)

A

B (24)

(24)

(9)

(12)

(24) (10) (1) C

(11)

(25)

(15) (13)

(24) T4 (2) B

(3)

A

T4 (17)

(16) (16)

T4

(6) (16) T3 C

T3 T3

(4) (18) (5)

(19)

(16)

(20) (22)

(21) T2

T3

(22) T2

(22)

T2

(22) T2

T3

FU-05148

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General Description FUEL INJECTION (FUEL SYSTEMS) (1) (2)

Fuel tank Fuel tank band RH

(12) (13)

Fuel sub level sensor upper plate Fuel sub level sensor gasket

(23) (24)

Rubber cap Cushion

(3) (4)

Fuel tank band LH Fuel delivery tube

(14) (15)

Fuel sub level sensor protector Fuel sub level sensor filter

(25)

Cushion

(5) (6) (7) (8) (9) (10)

Tube clamp Fuel sub delivery tube Fuel pump ASSY Fuel pump upper plate Fuel pump gasket Fuel sub level sensor upper plate cushion

(16) (17) (18) (19) (20) (21)

Retainer Stopper Heat shield cover Fuel tank protector RH Fuel tank protector LH Clip

(11)

Fuel sub level sensor

(22)

Self-locking nut

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Tightening torque:N·m (kgf-m, ft-lb) T1: 4.4 (0.4, 3.2) T2: 9 (0.9, 6.6) T3: 18 (1.8, 13.3) T4: 33 (3.4, 24.3)

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General Description FUEL INJECTION (FUEL SYSTEMS)

7. FUEL LINE (23) (26)

(16) T3

(25)

(1) (18) G

(1)

(32) (1)

T2

F

(28)

(20)

(24) (21)

H

(33) (1)

F

G

(27)

(31)

(22)

F

I

T5

(17) H

(30) T2

(19)

(29)

F (1) I (1) (15) (14)

(13) (1)

C

T3

(1)

T3 (12) (6)

T1

T1

(4)

(1)

(5)

C (1) (11)

(3)

(3) (1)

(1)

(2) (7)

A B

(10)

A B

T4

(8)

(9)

FU-05096

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General Description FUEL INJECTION (FUEL SYSTEMS) (1) (2)

Clip Fuel delivery hose A

(15) (16)

Air vent hose A Circulate tube

(29) (30)

Clamp Fuel tank pressure sensor bracket

(3)

Clamp

(17)

Air vent tube

(31)

Pressure hose

(4)

Fuel damper

(18)

Circulate hose

(32)

Fuel tank pressure sensor

(5)

Fuel delivery hose B

(19)

Vent tube

(33)

Vacuum hose

(6)

Connect check cover

(20)

Drain valve

(7) (8) (9) (10) (11) (12) (13)

Evaporation hose Fuel damper holder Damper bracket Fuel pipe ASSY Purge hose A Purge pipe Purge hose B

(21) (22) (23) (24) (25) (26) (27)

Canister Drain filter Canister protector Charge tube Canister drain tube Drain tube ASSY Clamp

(14)

Connector

(28)

Fuel filler hose

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Tightening torque:N·m (kgf-m, ft-lb) T1: 1.25 (0.1, 2.9) T2: 2.5 (0.3, 1.8) T3: 7.35 (0.7, 5.4) T4: 7.5 (0.8, 5.5) T5: 8 (0.8, 5.9)

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General Description FUEL INJECTION (FUEL SYSTEMS)

8. FUEL FILLER PIPE (3) (1) (2) (4)

(5) (10)

(6)

(11)

T3

(10) (12)

(13)

(7) (14)

T3 (8)

T2

T1

(8)

(9)

(15) T3 FU-05061

(1) (2) (3) (4) (5) (6) (7)

Fuel filler cap Fuel filler pipe protector Clip Neck holder A Neck holder B Fuel filler pipe Fuel filler pipe bracket A

(8) (9) (10) (11) (12) (13)

Fuel filler pipe bracket B Fuel filler pipe bracket C Clip Evaporation hose Grommet Evaporation pipe

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(14) (15)

Evaporation pipe protector Grommet

Tightening torque:N·m (kgf-m, ft-lb) T1: 1 (0.1, 0.7) T2: 7.35 (0.7, 5.4) T3: 7.5 (0.8, 5.5)

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General Description FUEL INJECTION (FUEL SYSTEMS)

9. FUEL PUMP (1) B (3)

A

B

(4)

(2) (2)

(5)

A (6)

A (7)

(11)

(10)

(8)

(11) (9)

FU-08400

(1)

Fuel filter assembly

(5)

Fuel pump

(9)

(2)

Pump module spring

(6)

Support rubber cushion

(10)

(3) (4)

Fuel pump harness Gasket spacer

(7) (8)

Fuel pump holder Fuel chamber ASSY

(11)

FU(H6DO)-16

Fuel level sensor (model with fuel level sensor bent in 3 locations) Fuel level sensor (model with fuel level sensor bent in 2 locations) Fuel temperature sensor

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General Description FUEL INJECTION (FUEL SYSTEMS)

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. • Place “NO OPEN FLAMES” signs near the working area. • Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can be spilled. If the oil spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing fuel.

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General Description FUEL INJECTION (FUEL SYSTEMS)

D: PREPARATION TOOL 1. ST ILLUSTRATION

TOOL NUMBER 1B022XU0

DESCRIPTION SUBARU SELECT MONITOR III KIT

Used for draining fuel and each inspection.

REMARKS

42099AE000

QUICK CONNECTOR RELEASE

Used for disconnecting quick connector of the engine compartment.

18471AA000

FUEL PIPE ADAPTER

Used for draining fuel.

ST1B022XU0

ST42099AE000

ST18471AA000

2. GENERAL TOOL TOOL NAME Circuit tester Oscilloscope

REMARKS Used for measuring resistance and voltage. Used for inspecting the waveform of each sensor.

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Throttle Body FUEL INJECTION (FUEL SYSTEMS)

2. Throttle Body

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

(A)

NOTE: Use new O-rings.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

C: INSPECTION 1. THROTTLE SENSOR (METHOD WITH CIRCUIT TESTER) 1) Remove the glove box lid assembly. 2) Turn the ignition switch to ON. (engine OFF) 3) Measure the voltage between ECM connector terminals.

(A) 7 6 5 4 3 17 16 15 14 13 12 11 27 26 25 24 23 22 21 34 33 32 31

(B)

(B)

ME-04447

2) Disconnect the ground cable from battery. 3) Remove the air intake boot assembly. 4) Disconnect the connector from the throttle body.

2 1 10 9 8 20 19 18 30 29 28

V FU-04656

(A) To ECM connector Throttle sensor

Main

Accelerator pedal Not depressed (Full closed)

Terminal No.

Approx. 0.6 V 18 (+) and 1 (–)

Depressed (Full opened) FU-05046

5) Disconnect the engine coolant hoses (A) from throttle body. 6) Remove the bolts which secure the throttle body to the intake manifold.

Sub

Not depressed (Full closed) Depressed (Full opened)

Standard

Approx. 4.01 V Approx. 1.48 V 28 (+) and 1 (–) Approx. 4.23 V

4) After inspection, install the related parts in the reverse order of removal.

(A) (A) FU-05047

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Throttle Body FUEL INJECTION (FUEL SYSTEMS)

2. THROTTLE SENSOR (METHOD WITH SUBARU SELECT MONITOR) 1) Turn the ignition switch to ON. (engine OFF) 2) Read the throttle opening angle signal and voltage of throttle sensor using Subaru Select Monitor.

Throttle sensor Main Sub

Throttle opening angle signal 0.0% 100.0%

Approx. 0.6 V Approx. 4.01 V

0.0% 100.0%

Approx. 1.48 V Approx. 4.23 V

Standard

3. OTHER INSPECTIONS 1) Check that the throttle body has no deformation, cracks or other damages. 2) Check that the engine coolant hose has no cracks, damage or loose part.

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

3. Intake Manifold

(6) Flow sensor connector (A)

A: REMOVAL 1) Remove the collector cover.

(E)

NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

(C)

(D)

ME-04399

(A) (B) (C) (D) (E)

(A)

(B)

(B)

Generator connector Terminal B Harness cover A/C compressor solenoid connector Flow sensor connector

(7) Slide the harness and connector to the battery side. 7) Disconnect the PCV hose and blow-by hose.

(B) ME-04447

2) Release the fuel pressure. 3) Disconnect the ground cable from battery. 4) Open the fuel filler lid and remove the fuel filler cap. 5) Remove the air cleaner case and air intake boot assembly. 6) Disconnect the following connector. (1) Remove the securing clips from the two locations on the fuel pipe protector LH.

FU-05054

8) Disconnect the connector (A) from throttle body. 9) Disconnect the engine harness connector (B).

(B) (A)

FU-04657 ME-04398

(2) Generator connector (3) Generator terminal B (4) Remove the harness cover from collector cover bracket. (5) A/C compressor solenoid connector

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

10) Disconnect the brake booster vacuum hose.

13) Remove the fuel pipe protector LH.

ME-04403

11) Remove the throttle body from the intake manifold. NOTE: Do not disconnect the inlet and outlet hoses of engine coolant.

FU-05137

14) Remove the engine harness from the fuel injector pipe LH. 15) Disconnect the connectors of the oil temperature sensor, engine coolant temperature sensor and intake oil flow control solenoid valve LH.

(C)

(B)

(A) FU-03311

FU-05142

12) Disconnect the fuel delivery hose and evaporation hose. CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. (1) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE

(A) Intake oil flow control solenoid valve LH (B) Oil temperature sensor (C) Engine coolant temperature sensor

16) Remove the bolts which hold fuel injector pipe LH to cylinder head.

FU-05138 ST

ME-04481

(2) Remove the clip and disconnect the evaporation hose.

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

17) Disconnect the connectors of the intake oil flow control solenoid valve RH.

• RH side

FU-03315 FU-03316

22) Remove the EGR pipe securing bolt.

18) Remove the fuel pipe protector RH.

FU-04660 FU-02119

19) Remove the engine harness from the fuel injector pipe RH. 20) Remove the bolts which hold the fuel injector pipe RH to the cylinder head.

23) Remove the intake manifold.

B: INSTALLATION 1) Install the intake manifold onto cylinder heads. NOTE: Use new O-rings.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) • RH side

FU-03313

21) Remove the bolts which hold the intake manifold to the cylinder head. • LH side FU-03315

• LH side

FU-05139

FU-05139

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

2) Install the EGR pipe securing bolt.

6) Connect the connectors of the intake oil flow control solenoid valve RH.

NOTE: Use a new gasket.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-03316

7) Install the bolts which hold fuel injector pipe LH to cylinder head. FU-04660

3) Install the bolts which hold fuel injector pipe RH to cylinder head. NOTE: Use a new seal ring.

NOTE: Use a new seal ring.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-05138

FU-03313

8) Connect the connectors of the oil temperature sensor, engine coolant temperature sensor and intake oil flow control solenoid valve LH.

4) Install the engine harness to fuel injector pipe RH. 5) Install the fuel pipe protector RH.

(C)

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

(B)

(A) FU-03311

(A) Intake oil flow control solenoid valve LH (B) Oil temperature sensor (C) Engine coolant temperature sensor

FU-02119

9) Install the engine harness to fuel injector pipe LH. 10) Install the fuel pipe protector LH.

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

13) Connect the brake booster vacuum hose.

ME-04403 FU-05137

11) Connect the fuel delivery hose (A) and evaporation hose (B).

14) Connect the connector (A) to throttle body. 15) Connect the engine harness connector (B).

NOTE: If fuel hoses or clamps are damaged, replace them with new parts.

(B) (A)

FU-04657

(B)

16) Connect the PCV hose and blow-by hose.

(A)

ME-04483

12) Install the throttle body to the intake manifold. NOTE: Use new O-rings.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb) FU-05054

17) Connect the following connectors. (1) Install the securing clips to the two locations on the fuel pipe protector LH.

FU-05142

ME-04398

(2) Generator connector (3) Generator terminal B

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

(4) Install the harness cover to the collector cover bracket. (5) A/C compressor solenoid connector (6) Flow sensor connector (A)

5) Remove the bolts which install fuel pipes on intake manifold.

(B)

(E)

(C)

(D) FU-04661 ME-04399

(A) (B) (C) (D) (E)

Generator connector Terminal B Harness cover A/C compressor solenoid connector Flow sensor connector

18) Install the air cleaner case and air intake boot assembly. 19) Connect the ground cable to battery. 20) Install the collector cover.

C: DISASSEMBLY 1) Remove the engine harness from intake manifold. 2) Remove the manifold absolute pressure sensor.

3) Remove the purge control solenoid valve. 4) Loosen the clamp which holds the fuel injector pipe to the fuel hose, and disconnect the pipe from the fuel hose.

FU-03320

6) Remove the EGR valve.

D: ASSEMBLY NOTE: When assembling the nipple, apply liquid gasket.

Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Tightening torque: 17 N·m (1.7 kgf-m, 12.5 ft-lb) 1) Install the EGR valve. 2) Tighten the bolts which install fuel pipes on intake manifold.

FU-03318

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Intake Manifold FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-04661

FU-03320

3) Connect the fuel injector pipe to fuel hose, and tighten the clamp screw.

Tightening torque: 1.25 N·m (0.1 kgf-m, 0.9 ft-lb)

FU-03318

4) Install the purge control solenoid valve. 5) Install the manifold absolute pressure sensor.

6) Install the engine harness to the intake manifold.

E: INSPECTION 1) Check that the intake manifold and fuel pipe have no deformation, cracks and other damages. 2) Check that the hose has no cracks, damage or loose part.

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Engine Coolant Temperature Sensor FUEL INJECTION (FUEL SYSTEMS)

4. Engine Coolant Temperature Sensor

B: INSTALLATION

A: REMOVAL

Tightening torque: 22 N·m (2.2 kgf-m, 16.2 ft-lb)

1) Remove the collector cover.

Install in the reverse order of removal.

NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle. FU-05055

C: INSPECTION (A)

1) Check that the engine coolant temperature sensor has no deformation, cracks or other damages. 2) Immerse the engine coolant temperature sensor and a thermometer in water.

(A)

(B)

(B) ME-04447

2) Disconnect the ground cable from battery. 3) Drain engine coolant. 4) Disconnect the connectors from the engine coolant temperature sensor.

CAUTION: Take care not to allow water to get into the engine coolant temperature sensor connector. Completely remove any water inside.

(A)

(B)

(C) FU-05055

5) Remove the engine coolant temperature sensor.

FU-04053

(A) Thermometer (B) Engine coolant temperature sensor (C) Hexagonal part height: To approx.1/3

3) Raise water temperature gradually, measure the resistance between the engine coolant temperature sensor terminals when the temperature is 20°C (68°F) and 80°C (176°F).

FU(H6DO)-28

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Engine Coolant Temperature Sensor FUEL INJECTION (FUEL SYSTEMS)

NOTE: Agitate the water for even temperature distribution.

2 1

FU-04662

Water temperature

Terminal No.

Standard

20°C (68°F) 80°C (176°F)

1 and 2

2.45±0.2 kΩ 0.318±0.013 kΩ

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Crankshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

5. Crankshaft Position Sensor A: REMOVAL

B: INSTALLATION

1) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

7) Disconnect the connector from crankshaft position sensor. Install in the reverse order of removal.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(A)

FU-03323

C: INSPECTION (B)

1. CRANKSHAFT POSITION SENSOR (METHOD WITH CIRCUIT TESTER)

(B) ME-04447

2) Disconnect the ground cable from battery. 3) Remove the air intake boot assembly. 4) Remove the throttle body from the intake manifold.

Measure the resistance between crankshaft position sensor terminals.

2 1

NOTE: Do not disconnect the inlet and outlet hoses of engine coolant. 5) Remove the service hole plug.

FU-04663

Terminal No. 1 and 2

ME-04284

6) Remove the crankshaft position sensor.

FU-03323

FU(H6DO)-30

Standard 1.86±0.186 kΩ

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Crankshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

2. CRANKSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE) 1) Prepare an oscilloscope. 2) Remove the glove box lid assembly. 3) Connect the probe to ECM connector. (A)

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 29 28 31 30 27 26

FU-04664

(A) To ECM connector Terminal No. 17 25

Probe + –

4) Start the engine and let it idle. 5) Check that the pattern is the same as the waveform and voltage shown below. 10ms 5V

0

(A)

FU-04057

(A) One crankshaft rotation

6) After inspection, install the related parts in the reverse order of removal.

3. OTHER INSPECTIONS Check that the crankshaft position sensor has no deformation, cracks or other damages.

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Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

6. Camshaft Position Sensor

5) Remove the fuel pipe protector LH.

A: REMOVAL 1. INTAKE SIDE 1) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

FU-05137

6) Disconnect the connector from intake camshaft position sensor LH.

(A)

(B)

(B)

FU-03324

ME-04447

2) Disconnect the ground cable from battery. 3) Remove the securing clips from the two locations on the fuel pipe protector LH.

7) Remove the intake camshaft position sensor LH.

FU-03325

ME-04398

4) Disconnect the PCV hose and blow-by hose.

8) Remove the intake camshaft position sensor RH in the same procedure as LH side.

2. EXHAUST SIDE 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the under cover. 4) Disconnect the connector from exhaust camshaft position sensor LH.

FU-05054

FU-03326

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Camshaft Position Sensor FUEL INJECTION (FUEL SYSTEMS)

5) Remove the exhaust camshaft position sensor LH.

Camshaft position sensor

Terminal No.

Probe

RH LH RH and LH

24 16 30

+ + –

• Exhaust camshaft position sensor 7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 29 28 31 30 27 26

FU-03327

(A)

6) Remove the exhaust camshaft position sensor RH in the same procedure as LH side.

B: INSTALLATION 1. INTAKE SIDE

FU-04666

Install in the reverse order of removal.

(A) To ECM connector

Tightening torque: Intake camshaft position sensor 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) Fuel pipe protector 19 N·m (1.9 kgf-m, 14.0 ft-lb)

Camshaft position sensor RH LH RH and LH

2. EXHAUST SIDE Tightening torque: Exhaust camshaft position sensor 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

Terminal No.

Probe

23 29 30

+ + –

4) Start the engine and let it idle. 5) Check that the pattern is the same as the waveform and voltage shown below.

C: INSPECTION 1. CAMSHAFT POSITION SENSOR (METHOD WITH OSCILLOSCOPE)

RH 0

(A)

1) Prepare an oscilloscope. 2) Remove the glove box lid assembly. 3) Connect the probe to ECM connector. • Intake camshaft position sensor

LH 0

(A)

5V 50ms

FU-04060

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 29 28 31 30 27 26

(A) One camshaft rotation

6) After inspection, install the related parts in the reverse order of removal.

(A)

2. OTHER INSPECTIONS Check that the camshaft position sensor has no deformation, cracks or other damages. FU-04665

(A) To ECM connector

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Knock Sensor FUEL INJECTION (FUEL SYSTEMS)

7. Knock Sensor

B: INSTALLATION

A: REMOVAL

1) Install the knock sensor to the cylinder block.

1) Remove the collector cover.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

NOTE: For the knock sensor installation angle, refer to the figure below. 30˚

45˚

10˚

(A) FU-05058

(B)

(B) ME-04447

2) Disconnect the ground cable from battery. 3) Remove the intake manifold. 4) Disconnect the knock sensor connector. 5) Remove the knock sensor from cylinder block.

2) Connect the knock sensor connector. 3) Install the intake manifold. 4) Connect the ground cable to battery. 5) Install the collector cover.

C: INSPECTION 1) Check that the knock sensor has no deformation, cracks or other damages. 2) Measure the resistance between knock sensor terminals.

2 1

FU-05056 FU-04663

Terminal No. 1 and 2

FU(H6DO)-34

Standard 560±28 kΩ

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Throttle Position Sensor FUEL INJECTION (FUEL SYSTEMS)

8. Throttle Position Sensor A: SPECIFICATION Throttle body is a non-disassembled part, so do not remove the throttle position sensor from throttle body. Refer to “Throttle Body” for removal and installation procedure.

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Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS)

9. Manifold Absolute Pressure Sensor

B: INSTALLATION

A: REMOVAL

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

1) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

C: INSPECTION 1) Check that the manifold absolute pressure sensor has no deformation, cracks or other damages. 2) Connect dry-cell battery positive terminal to terminal No. 3 and dry-cell battery ground terminal to terminal No. 2, circuit tester negative terminal to terminal No. 2 and the circuit tester positive terminal to terminal No. 1. NOTE: • Use new dry-cell batteries. • Using circuit tester, check the voltage of a single dry-cell battery is 1.6 V or more. And also check the voltage of three batteries in series is between 4.8 V and 5.2 V.

(A)

(B)

Install in the reverse order of removal.

(B) ME-04447

3 2 1

2) Disconnect the ground cable from battery. 3) Disconnect the manifold pressure sensor connector.

V

FU-04798

1.5V

4) Remove the manifold pressure sensor and the filter and hose from intake manifold.

1.5V 4.8

1.5V

5.2V FU-04667

3) Connect the Mighty Vac to the pressure port (A) of manifold absolute pressure sensor.

FU-04799

(A)

FU(H6DO)-36

FU-04668

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Manifold Absolute Pressure Sensor FUEL INJECTION (FUEL SYSTEMS)

4) Check the voltage when generating vacuum and positive pressure using Mighty Vac. CAUTION: Do not apply vacuum of less than –88 kPa (–0.9 kgf/cm2, –12.8 psi). Doing so may damage the manifold absolute pressure sensor. NOTE: When vacuum occurs at the pressure port of manifold absolute pressure sensor, the voltage will drop from the value as in step 3). When positive pressure occurs, on the other hand, the voltage will rise. Pressure

Terminal No.

Standard

2 (+) and 1 (–)

Approx. 1 V (when 25°C (77°F)) Approx. 2.6 V (when 25°C (77°F)) Approx. 4.2 V (when 25°C (77°F))

–88 kPa (–0.9 kgf/cm2, –12.8 psi) –35 kPa (–0.4 kgf/cm2, –5.1 psi) 19 kPa (–0.2 kgf/cm2, 2.8 psi)

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Mass Air Flow and Intake Air Temperature Sensor FUEL INJECTION (FUEL SYSTEMS)

10.Mass Air Flow and Intake Air Temperature Sensor

2) Check that the voltage changes when air is blown to the mass air flow sensor unit from arrow direction.

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector (A) from air flow and intake air temperature sensor.

(A)

FU-04672

2. CHECK INTAKE AIR TEMPERATURE SENSOR UNIT FU-05051

Measure the resistance between intake air temperature sensor terminals.

3) Remove the mass air flow and intake air temperature sensor.

5 4 3 2 1

FU-04673 FU-05052

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 1 N·m (0.1 kgf-m, 0.7 ft-lb)

Temperature –20°C (–4°F) 20°C (68°F) 60°C (140°F)

Terminal No. 1 and 2

Standard 16.0±2.4 kΩ 2.45±0.24 kΩ 0.58±0.087 kΩ

3. OTHER INSPECTIONS

C: INSPECTION 1. CHECK MASS AIR FLOW SENSOR UNIT 1) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, circuit tester positive terminal to terminal No. 5 and the circuit tester negative terminal to terminal No. 4.

1) Check that the mass air flow and intake air temperature sensor has no deformation, cracks or other damages. 2) Check that the mass air flow and intake air temperature sensor has no dirt.

5 4 3 2 1

V FU-04671

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EGR Valve FUEL INJECTION (FUEL SYSTEMS)

11.EGR Valve

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

NOTE: Use a new gasket.

Tightening torque: EGR valve 19 N·m (1.9 kgf-m, 14.0 ft-lb) EGR pipe 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(A)

FU-02133

(B)

(B) ME-04447

2) Disconnect the ground cable from battery. 3) Remove the air intake boot assembly. 4) Remove the starter. 5) Remove the EGR pipe from EGR valve and cylinder head. 6) Remove the EGR valve from intake manifold.

C: INSPECTION 1) Check that the EGR valve has no deformation, cracks or other damages. 2) Measure the resistance between EGR valve terminals.

3 2 1 6 5 4

FU-04674

FU-02133

7) Disconnect the connector from EGR valve.

FU(H6DO)-39

Terminal No. 2 and 1 2 and 3 5 and 4 5 and 6

Standard 22±2 Ω 22±2 Ω 22±2 Ω 22±2 Ω

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Fuel Injector FUEL INJECTION (FUEL SYSTEMS)

12.Fuel Injector

9) Remove the bolt which holds fuel injector pipe onto cylinder head.

A: REMOVAL 1. RH SIDE 1) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

FU-03329

10) Remove the fuel injector while lifting up the fuel injector pipe.

2. LH SIDE 1) Remove the collector cover.

(A)

(A)

(B)

(B) ME-04447

2) Release the fuel pressure. 3) Disconnect the ground cable from battery. 4) Open the fuel filler lid and remove the fuel filler cap. 5) Remove the air cleaner case and air intake boot assembly. 6) Remove the fuel pipe protector RH.

NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

(A)

(B)

(B) ME-04447

2) Release the fuel pressure. 3) Remove the battery. 4) Open the fuel filler lid and remove the fuel filler cap. 5) Remove the securing clips from the two locations on the fuel pipe protector LH. FU-02119

7) Disconnect the connector from fuel injector. 8) Remove the engine harness from the fuel injector pipe RH.

ME-04398

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Fuel Injector FUEL INJECTION (FUEL SYSTEMS)

6) Disconnect the PCV hose and blow-by hose.

B: INSTALLATION 1. RH SIDE Install in the reverse order of removal. NOTE: Use a new seal ring.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) FU-05054

7) Remove the fuel pipe protector LH.

FU-03329

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) FU-05137

8) Disconnect the connector from fuel injector. 9) Remove the engine harness from the fuel injector pipe LH. 10) Remove the bolt which holds fuel injector pipe onto cylinder head.

FU-02119

2. LH SIDE Install in the reverse order of removal. NOTE: Use a new seal ring. FU-05041

11) Remove the fuel injector while lifting up the fuel injector pipe.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-05141

FU(H6DO)-41

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Fuel Injector FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

FU-05137

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Oil Flow Control Solenoid Valve FUEL INJECTION (FUEL SYSTEMS)

13.Oil Flow Control Solenoid Valve A: REMOVAL 1. INTAKE SIDE 1) Remove the collector cover.

2. EXHAUST SIDE 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the under cover. 4) Disconnect the connector from the exhaust oil flow control solenoid valve LH.

NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle. FU-03333

(A)

5) Remove the exhaust oil flow control solenoid valve LH.

(A)

(B)

(B) ME-04447

2) Disconnect the ground cable from battery. 3) Disconnect the connector from the intake oil flow control solenoid valve RH. FU-03334

6) Remove the exhaust oil flow control solenoid valve RH in the same procedure as the exhaust oil flow control solenoid valve LH.

B: INSTALLATION 1. INTAKE SIDE Install in the reverse order of removal. FU-03331

4) Remove the intake oil flow control solenoid valve RH.

Tightening torque: Intake oil flow control solenoid valve 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

2. EXHAUST SIDE Tightening torque: Exhaust oil flow control solenoid valve 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-03332

5) Remove the intake oil flow control solenoid valve LH in the same procedure as the intake oil flow control solenoid valve RH.

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Oil Flow Control Solenoid Valve FUEL INJECTION (FUEL SYSTEMS)

C: INSPECTION 1) Check that the oil flow control solenoid valve has no deformation, cracks or other damages. 2) Measure the resistance between oil flow control solenoid valve terminals.

2 1 4 3

FU-04675

Terminal No.

Standard

1 and 2

7.4±0.5 Ω (when 20°C (68°F))

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Oil Temperature Sensor FUEL INJECTION (FUEL SYSTEMS)

14.Oil Temperature Sensor

C: INSPECTION

A: REMOVAL

1) Check that the oil temperature sensor has no deformation, cracks or other damages. 2) Measure the resistance between oil temperature sensor terminals.

1) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

2 1

FU-04676

(A)

(A)

(B)

(B) ME-04447

2) Disconnect the ground cable from battery. 3) Disconnect the connector from oil temperature sensor.

FU-05057

4) Remove the oil temperature sensor.

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 22 N·m (2.2 kgf-m, 16.2 ft-lb)

FU(H6DO)-45

Terminal No.

Standard

1 and 2

2.45±0.2 Ω (when 20°C (68°F))

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Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS)

15.Front Oxygen (A/F) Sensor

6) Remove the front oxygen (A/F) sensor.

A: REMOVAL

CAUTION: When removing the front oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.

1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Disconnect the connector (A) of the front oxygen (A/F) sensor.

(A)

(A)

(B)

(A)

FU-05039

(A) Front oxygen sensor RH (B) Front oxygen sensor LH

FU-05037

4) Remove the catalytic converter lower cover. (U5 model)

B: INSTALLATION CAUTION: If lubricant is spilt over the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to the protector of front oxygen (A/F) sensor.

Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the front oxygen (A/F) sensor.

FU-05038

5) Apply spray-type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more.

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Front Oxygen (A/F) Sensor FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 21 N·m (2.1 kgf-m, 15.5 ft-lb)

4) Connect the connector (A) of front oxygen (A/F) sensor.

(A) (A)

(B) (A)

FU-05037

FU-05039

5) Lower the vehicle. 6) Connect the ground cable to battery.

(A) Front oxygen sensor RH (B) Front oxygen sensor LH

3) Install the catalytic converter lower cover. (U5 model)

Tightening torque: 13 N·m (1.3 kgf-m, 9.6 ft-lb)

C: INSPECTION 1) Check that the front oxygen (A/F) sensor has no deformation, cracks or other damages. 2) Measure the resistance between front oxygen (A/F) sensor terminals.

2 1 4 3

FU-04677

FU-05038

FU(H6DO)-47

Terminal No.

Standard

3 and 4

2.4±0.24 Ω (when 20°C (68°F))

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Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS)

16.Rear Oxygen Sensor

B: INSTALLATION

A: REMOVAL

CAUTION: If lubricant is spilt over the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. 1) Before installing rear oxygen sensor, apply the anti-seize compound only to the threaded portion of rear oxygen sensor to make the next removal easier.

1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the front exhaust pipe. 4) Apply spray-type lubricant to the threaded portion of rear oxygen sensor, and leave it for one minute or more. 5) Remove the rear oxygen sensor. CAUTION: When removing the rear oxygen sensor, wait until exhaust pipe cools, otherwise it will damage the exhaust pipe.

CAUTION: Never apply anti-seize compound to the protector of rear oxygen sensor.

Anti-seize compound: NEVER-SEEZ NSN, JET LUBE SS-30 or equivalent 2) Install the rear oxygen sensor. Tightening torque: 21 N·m (2.1 kgf-m, 15.5 ft-lb)

(A)

(A)

(B)

(B)

FU-04922

(A) Rear oxygen sensor RH (B) Rear oxygen sensor LH FU-04922

(A) Rear oxygen sensor RH (B) Rear oxygen sensor LH

3) Install the front exhaust pipe. 4) Lower the vehicle. 5) Connect the ground cable to battery.

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Rear Oxygen Sensor FUEL INJECTION (FUEL SYSTEMS)

C: INSPECTION 1) Check the rear oxygen (A/F) sensor for deformation, cracks or other damages. 2) Measure the resistance between rear oxygen (A/ F) sensor terminals.

2 1 4 3

FU-04678

Terminal No. 1 and 2

5.6+0.8

Standard –0.6 Ω (when 20°C (68°F))

FU(H6DO)-49

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Engine Control Module (ECM) FUEL INJECTION (FUEL SYSTEMS)

17.Engine Control Module (ECM) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box lid assembly. 3) Disconnect the connectors from ECM.

FU-05041

4) Remove the ECM from vehicle.

FU-05042

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) CAUTION: • When the ECM of model with immobilizer has been replaced, be sure to perform the registration of immobilizer system. (Refer to “PC application help for Subaru Select Monitor”.) • If replacing ECM or the bracket, replace both parts with new parts at a time. • After installing the bracket to ECM, do not separate the bracket. • If the bracket has been installed to ECM in the wrong direction, replace both parts to new parts. NOTE: When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system.

C: INSPECTION Check that the ECM has no deformation, cracks or other damages.

FU(H6DO)-50

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Main Relay FUEL INJECTION (FUEL SYSTEMS)

18.Main Relay A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box lid assembly. 3) Remove the main relay.

3) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, and measure the resistance between the main relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2

FU-05043

B: INSTALLATION

3 4

Install in the reverse order of removal.

C: INSPECTION 1) Check that the main relay has no deformation, cracks or other damages. 2) Measure the resistance between main relay terminals.

FU-04077

Terminal No. 1 and 2 (1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2 3 4

FU-04076

Terminal No. 1 and 2

Standard 1 MΩ or more

3 and 4

130.4 — 230.8 Ω (When 20°C (68°F))

FU(H6DO)-51

Standard Less than 1 Ω

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Fuel Pump Relay FUEL INJECTION (FUEL SYSTEMS)

19.Fuel Pump Relay A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box lid assembly. 3) Remove the fuel pump relay.

3) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, and measure the resistance between the fuel pump relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2

FU-05044

B: INSTALLATION

3 4

Install in the reverse order of removal.

C: INSPECTION 1) Check that the fuel pump relay has no deformation, cracks or other damages. 2) Measure the resistance between fuel pump relay terminals.

FU-04077

Terminal No. 1 and 2 (1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2 3 4

FU-04076

Terminal No. 1 and 2

Standard 1 MΩ or more

3 and 4

93.8 — 136.4 Ω (When 20°C (68°F))

FU(H6DO)-52

Standard Less than 1 Ω

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Electronic Throttle Control Relay FUEL INJECTION (FUEL SYSTEMS)

20.Electronic Throttle Control Relay A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box lid assembly. 3) Remove the electronic throttle control relay.

3) Connect battery positive terminal to terminal No. 3 and battery ground terminal to terminal No. 4, and measure the resistance between the electronic throttle control relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2

FU-05045

B: INSTALLATION

3 4

Install in the reverse order of removal.

C: INSPECTION 1) Check that the electronic throttle control relay has no deformation, cracks or other damages. 2) Measure the resistance between electronic throttle control relay terminals.

(1)

(2)

(3)

(2)

(1)

(3)

(4)

(4)

1 2 3 4

FU-04076

Terminal No. 1 and 2

Standard 1 MΩ or more

3 and 4

93.8 — 136.4 Ω (When 20°C (68°F))

FU(H6DO)-53

FU-04077

Terminal No. 1 and 2

Standard Less than 1 Ω

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Fuel Pump Control Unit FUEL INJECTION (FUEL SYSTEMS)

21.Fuel Pump Control Unit

• OUTBACK model

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the trunk trim panel assembly-side RH. (Sedan model) 3) Remove the right side rear quarter trim. (OUTBACK model) 4) Remove the fuel pump control unit. • Sedan model

FU-04796

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

C: INSPECTION Check that the fuel pump control unit has no deformation, cracks or other damages. FU-04793

• OUTBACK model

FU-04794

5) Disconnect the connector from fuel pump control unit. • Sedan model

FU-04795

FU(H6DO)-54

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Fuel FUEL INJECTION (FUEL SYSTEMS)

22.Fuel A: PROCEDURE 1. RELEASING OF FUEL PRESSURE WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Remove the fuse of fuel pump from main fuse box.

NOTE: • If the fuel pump cannot be driven, refer to the procedures for draining from the fuel filler hose.

• Be careful not to let the battery run-out. 1) Release the fuel pressure. 2) Remove the collector cover. 3) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose (A). ST 42099AE000 QUICK CONNECTOR RELEASE CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth.

(A) ST

FU-05053 (A) FU-04680

(A) Front side

2) Start the engine and run it until it stalls. 3) After the engine stalls, crank it for five more seconds. 4) Turn the ignition switch to OFF. 5) Install the fuse of fuel pump to the main fuse box.

2. DRAINING FUEL (WITH SUBARU SELECT MONITOR) WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel.

4) Connect ST to the fuel delivery hose. ST 18471AA000 FUEL PIPE ADAPTER 5) Connect the gasoline proof hose to the fuel damper, and put the hose end into the container. 6) Drive the fuel pump and drain the fuel using Subaru Select Monitor. (Refer to “PC application help for Subaru Select Monitor”.) CAUTION: Be careful not to spill fuel. 7) Install the related parts in the reverse order after draining the fuel.

3. DRAINING FUEL (THROUGH THE FUEL FILLER HOSE) WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Be careful not to spill fuel. • Fuel may remain in the fuel filler pipe. Draining the fuel from the fuel filler pipe through the fill opening using the gasoline proof pump and the gasoline proof hose (ø10 or less) before the operation.

FU(H6DO)-55

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Fuel FUEL INJECTION (FUEL SYSTEMS)

1) Lift up the vehicle. 2) Remove the rear exhaust pipe and muffler. 3) Open the fuel filler lid and remove the fuel filler cap. 4) Drain the fuel from the fuel filler pipe through the filler opening using the gasoline proof pump and the gasoline proof hose (ø10 or less). 5) Disconnect the fuel filler hoses from the fuel filler pipe. CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth.

FU-04803

6) Set the container under the vehicle and insert the gasoline proof hose (ø10 or less) into the fuel filler hose to drain the fuel. CAUTION: Be careful not to spill fuel. 7) Install the related parts in the reverse order after draining the fuel.

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb)

FU(H6DO)-56

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

23.Fuel Tank

7) Remove the service hole cover of fuel sub level sensor.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery. 4) Remove the rear seat cushion. 5) Remove the clips (A) and seat cushion hooks (B), and turn over the floor mat (C).

FU-05070

8) Disconnect the quick connector on the fuel delivery tube (A). (A)

FU-05069 (C)

(B)

(A)

(A)

(B) FU-04990

9) Remove the rear wheels. 10) Lift up the vehicle. 11) Remove the rear ABS wheel speed sensor from the rear housing.

6) Remove the service hole cover of fuel pump. (1) Disconnect the fuel cord connector (A), and remove the clip (B). (2) Remove the screw (C). (3) Push the grommet (D) down and remove the service hole cover. (C)

FU-04994

(D)

12) Remove the rear ABS wheel speed sensor harness bracket from the upper arm.

(B) (C) (A)

FU-04991

FU-04087

FU(H6DO)-57

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

13) Remove the rear brake hose bracket from rear housing.

18) Remove the propeller shaft. 19) Remove the clip (A) securing the fuel tank protector and heat shield cover. 20) Remove the bolts (B) and nuts (C) securing the fuel tank protector, and remove the fuel tank protector. (B)

(B)

(B) (C)

(C)

FU-04995

14) Remove the rear disc brake assembly and tie it to the body side of the vehicle.

(A)

FU-04997

21) Remove the bolts and nuts securing the heat shield cover and remove the heat shield cover.

FU-04998

22) Remove the rear suspension assembly.

FU-04996

15) Remove the parking brake cable from parking brake assembly. 16) Remove the rear exhaust pipe and muffler. 17) Remove the heat shield cover.

WARNING: A helper is required to perform this work. (1) Support the rear differential with the transmission jack. (2) Remove the bolt and nut which secure rear shock absorber to rear suspension arm.

FU-03359

(A) DS-00472

(A) Heat shield cover

FU(H6DO)-58

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

(3) Remove the bolts which secure the rear suspension assembly to the body.

25) Disconnect the fuel filler hose (A) and circulate hose (B) from the fuel filler pipe assembly. (B)

(A)

FU-04999

(4) Remove the rear suspension assembly. 23) Disconnect the air vent hose from the fuel tank.

FU-05149

26) Support the fuel tank with a transmission jack, remove the bolts from the fuel tank band, and remove the fuel tank from the vehicle. WARNING: • A helper is required to perform this work. • Fuel may remain in the fuel tank. This will cause the left and right sides to be unbalanced. Be careful not to drop the fuel tank when removing.

FU-05083

24) Disconnect the quick connector of the circulate tube from evaporation pipe. NOTE: Disconnect the quick connector as shown in the figure. 1

FU-05004

2

B: INSTALLATION 1) Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band. WARNING: A helper is required to perform this work. 1

FU-05002

FU-05004 FU-05003

2) Securely insert the fuel filler hose (A) and circulate hose (B) to the spool, then attach the clamp or clip as shown in the figure.

FU(H6DO)-59

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb)

• Make sure that the quick connector is securely connected.

(B)

(A)

FU-05036

FU-05149

(1)

(2)

(3)

(4)

L/2 L FU-05003

FU-04500

(1) (2) (3) (4)

4) Connect the air vent hose to fuel tank.

Hose Clamp or clip Spool Pipe

3) Connect the quick connector of the circulate tube to the evaporation pipe as shown in the figure. CAUTION: • Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.

FU-05083

5) Tighten the bolts of the fuel tank band in the order shown in the figure.

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb) 1

3

2

4 FU-05005

6) Install the rear suspension assembly. WARNING: A helper is required to perform this work. (1) Support the rear differential with the transmission jack.

FU(H6DO)-60

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

(2) While supporting the rear suspension assembly, install the rear suspension assembly to the body.

Tightening torque: T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb) T2: 200 N·m (20.4 kgf-m, 147.5 ft-lb)

Tightening torque: Nut (C): 9 N·m (0.9 kgf-m, 6.6 ft-lb) Bolt (B): 18 N·m (1.8 kgf-m, 13.3 ft-lb) (B)

(B)

(B) (C)

(C)

T2

(A)

T2

FU-04997

T1

T1 FU-05006

(3) Install the rear shock absorber to the rear suspension arm.

9) Install the propeller shaft. 10) Install the heat shield cover.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

NOTE: Use a new self-locking nut.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb)

(A) DS-00472

(A) Heat shield cover

FU-03359

7) Install the heat shield cover.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

11) Install the rear exhaust pipe and muffler. 12) Lower the vehicle. 13) Connect the parking brake cable to the parking brake assembly. 14) Install the rear disc brake assembly.

Tightening torque: 66 N·m (6.7 kgf-m, 48.7 ft-lb)

FU-04998

8) Install the bolts (B) and nuts (C) securing the fuel tank protector and install the clip (A) securing the fuel tank protector and heat shield cover. FU-04546

FU(H6DO)-61

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

15) Install the rear brake hose bracket to the rear housing.

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

19) Connect the quick connector of the fuel delivery tube (A). (A)

FU-05069 FU-04995

16) Install the rear ABS wheel speed sensor harness bracket to the upper arm.

20) Install the service hole cover of fuel sub level sensor.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

FU-05070

21) Install the service hole cover of the fuel pump, and install the connector and clip. (C)

FU-04087

17) Install the rear ABS wheel speed sensor to the rear housing.

(D)

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(B) (C) (A)

(A) (B) (C) (D) FU-04994

18) Install the rear wheels.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb)

FU(H6DO)-62

Connector Clip Screw Grommet

FU-04991

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Fuel Tank FUEL INJECTION (FUEL SYSTEMS)

22) Set the floor mat (C), and install clips (A) and seat cushion hooks (B).

(C)

(B)

(A)

(A)

(B) FU-04990

23) Install the rear seat cushion. 24) Connect the ground cable to battery. 25) Inspect the wheel alignment and adjust if necessary.

C: INSPECTION 1) Check that the fuel tank and fuel pipe have no deformation, cracks and other damages. 2) Check that the fuel hose has no cracks, damage or loose part.

FU(H6DO)-63

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Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS)

24.Fuel Filler Pipe A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area.

11) Disconnect the evaporation hose (A) from fuel filler pipe assembly and remove the bolts and nuts securing the fuel filler pipe assembly to the vehicle body.

CAUTION: Be careful not to spill fuel. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery. 4) Open the fuel filler lid, and remove the filler cap. 5) Turn the fuel filler pipe protector in the direction of the arrow to unlock and remove it.

(A)

FU-05150

12) Remove the fuel filler pipe assembly from the underside of the vehicle. FU-04044

6) Remove the rear wheel RH. 7) Lift up the vehicle. 8) Remove the rear mud guard RH. 9) Remove the rear sub frame. 10) Disconnect the fuel filler hose (A) and circulate hose (B) from the fuel filler pipe assembly.

B: INSTALLATION 1) Open the fuel filler lid. 2) Insert the fuel filler pipe assembly into the rubber saucer from inside of the rear fender. 3) Install the fuel filler pipe assembly to the vehicle body and connect the evaporation hose (A) and circulate hose (B) to the fuel filler pipe assembly.

(B)

(A)

FU-05149

FU(H6DO)-64

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Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

Tightening torque: 2.5 N·m (0.3 kgf-m, 1.8 ft-lb) (B)

(A)

(A)

FU-05149

(1)

(2)

(3)

(4)

L/2 L

FU-04500

FU-05150

(1) (2) (3) (4)

4) Align the cutout on the fuel filler pipe protector and the protrusion of the neck holder and insert them all the way, and then turn the fuel filler pipe protector in the direction of the arrow until it is locked.

Hose Clamp or clip Spool Pipe

6) Install the rear sub frame. 7) Install the rear mud guard RH. 8) Lower the vehicle. 9) Install the rear wheel RH.

FU-04104

5) Securely insert the fuel filler hose (A) and circulate hose (B) to the spool, then attach the clamp or clip as shown in the figure.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb) 10) Connect the ground cable to battery. 11) Inspect the wheel alignment and adjust if necessary.

FU(H6DO)-65

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Fuel Filler Pipe FUEL INJECTION (FUEL SYSTEMS)

C: DISASSEMBLY

E: INSPECTION

Remove the fuel filler pipe bracket from the fuel filler pipe.

Check that the fuel filler pipe does not have deformation, cracks or other damages.

FU-05009

D: ASSEMBLY Install the fuel filler pipe bracket to the fuel filler pipe.

Tightening torque: 7.35 N·m (0.7 kgf-m, 5.4 ft-lb)

FU-05009

FU(H6DO)-66

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Fuel Pump FUEL INJECTION (FUEL SYSTEMS)

25.Fuel Pump A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area.

7) Disconnect the connector (A) from fuel pump, and remove the clip (B) securing the harness. 8) Disconnect the quick connector of fuel delivery tube (C) and fuel sub delivery tube (D).

CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: Fuel pump assembly consists of fuel pump, fuel filter, fuel chamber and fuel level sensor. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery. 4) Remove the rear seat cushion. 5) Remove the clips (A) and seat cushion hooks (B), and turn over the floor mat (C).

(D) (C) (A)

(B)

FU-05063

9) Remove the nuts securing the fuel pump upper plate to the fuel tank and remove the fuel pump upper plate.

FU-04534

10) Remove the fuel pump assembly from the fuel tank.

B: INSTALLATION

(C)

(B)

(A)

(A)

(B) FU-04990

6) Remove the service hole cover. (1) Disconnect the fuel cord connector (A), and remove the clip (B). (2) Remove the screw (C). (3) Push the grommet (D) down and remove the service hole cover. (C)

Install in the reverse order of removal while being careful of the following. • Make sure the sealing portion is free from fuel or foreign matter before installation. • Align protrusion (A) of the gasket to the position shown in the figure. • Insert the protrusion (B) of gasket to the fuel pump upper plate. (3 places) • Align the protrusion (C) of fuel pump assembly with the cutout on the fuel pump upper plate. • Tighten the nuts to the specified torque in the order as shown in the figure. NOTE: Use a new gasket and retainer.

(D)

(B) (C) (A)

FU-04991

FU(H6DO)-67

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Fuel Pump FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 4.4 N·m (0.4 kgf-m, 3.2 ft-lb) 2

(C)

4

7

(B)

(B) 5

6

(a)

3

8 (B)

1

(A)

FU-05064

(a) Front side of vehicle

C: INSPECTION 1) Check that the fuel pump has no deformation, cracks or other damages. 2) Connect battery positive terminal to terminal No. 5 and battery ground terminal to terminal No. 6, and inspect the fuel pump operation. WARNING: • Wipe off fuel completely. • Keep the battery as far apart from fuel pump as possible. • Do not run the fuel pump for a long time under non-load condition. 2 1 4 3 6 5

FU-04110

FU(H6DO)-68

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Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS)

26.Fuel Level Sensor

4) Press two claws (A) of the fuel level sensor, and slide the fuel level sensor in the direction of the arrow to remove the fuel level sensor.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area.

(A)

(A)

CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. NOTE: The fuel level sensor is built in fuel pump assembly. 1) Remove the fuel pump assembly. 2) Disconnect the connector from the fuel filter assembly.

FU-05015

B: INSTALLATION Install in the reverse order of removal.

C: INSPECTION 1) Check that the fuel level sensor has no damage. 2) Measure the fuel level sensor float position. NOTE: When inspecting the fuel level sensor, perform the work with the sensor installed to the fuel pump. • Model with fuel level sensor bent in 3 locations

(1) FU-05065

3) Remove the harness from the hooks (A) on the fuel chamber assembly and remove the fuel temperature sensor (B) from fuel chamber assembly.

(A)

(3)

(B)

(2) (B)

FU-05067

(1) FULL (2) EMPTY (3) Fuel tank seating surface

(A)

FU-05066

Float position FULL to Fuel tank seating surface (A) EMPTY to Fuel tank seating surface (B)

FU(H6DO)-69

Standard 126.4±4 mm (4.976±0.157 in) 11.0±4 mm (0.433±0.157 in)

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Fuel Level Sensor FUEL INJECTION (FUEL SYSTEMS)

• Model with fuel level sensor bent in 2 locations

• Model with fuel level sensor bent in 2 locations

(1) (A) (A) (2) (3)

(B)

(B)

FU-08401

(1) FULL (2) EMPTY (3) Fuel tank seating surface Float position FULL to Fuel tank seating surface (A) EMPTY to Fuel tank seating surface (B)

2 1 4 3 6 5 Standard

120.9±4 mm (4.759±0.157 in) 14.8±4 mm (0.583±0.157 in)

3) Measure the resistance between fuel level sensor terminals. • Model with fuel level sensor bent in 3 locations

FU-08402

Float position FULL (A) EMPTY (B)

(A)

(B)

2 1 4 3 6 5

FU-05068

FU(H6DO)-70

Terminal No. 1 and 4

Standard 2.0±1.0 Ω 31.9±1.0 Ω

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Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS)

27.Fuel Sub Level Sensor

8) Disconnect the quick connector on the fuel sub delivery tube (B).

A: REMOVAL

(A)

WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. 1) Release the fuel pressure. 2) Drain fuel. 3) Disconnect the ground cable from battery. 4) Remove the rear seat cushion. 5) Remove the service hole cover.

(B)

FU-05072

9) Remove the nuts securing the fuel sub level sensor upper plate to the fuel tank and remove the fuel sub level sensor upper plate.

FU-04569

10) Remove the fuel sub level sensor from the fuel tank.

B: INSTALLATION FU-05070

6) Disconnect the connector (A) from fuel sub level sensor, and remove the clip (B) securing the fuel cord from fuel sub level sensor protector.

(B)

(A)

Install in the reverse order of removal while being careful of the following. • Make sure the sealing portion is free from fuel or foreign matter before installation. • Align protrusion (A) of the gasket to the position shown in the figure. • Align protrusion (B) of the fuel sub level sensor to the cutout in the fuel sub level sensor upper plate. • After tightening the bolts to the specified torque in the order indicated in the figure, install the fuel sub level sensor protector. NOTE: Use a new gasket and retainer.

FU-05071

7) Remove the bolts (A) securing the fuel sub level sensor protector to the fuel sub level sensor upper plate, and remove the fuel sub level sensor protector.

FU(H6DO)-71

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Fuel Sub Level Sensor FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: 4.4 N·m (0.4 kgf-m, 3.2 ft-lb)

3) Measure the resistance between fuel sub level sensor terminals.

4 2

(A)

6 5 (a)

1

(B) 3 (A)

(B)

FU-04533

(a) Front side of vehicle

2 1

FU-04214 FU-05073

C: INSPECTION 1) Check that the fuel sub level sensor has no damage. 2) Measure the fuel sub level sensor float position. (A)

Float position FULL (A) EMPTY (B)

(1) (3)

(B)

(2) FU-04213

(1) FULL (2) EMPTY (3) Datum points Float position FULL to Datum point (A)

Standard 6.4±3.5 mm (0.252±0.138 in)

EMPTY to Datum point (B)

163.3±3.5 mm (6.429±0.138 in)

FU(H6DO)-72

Terminal No. 1 and 2

Standard 2.0±1.0 Ω 62.1±1.0 Ω

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Fuel Filter FUEL INJECTION (FUEL SYSTEMS)

28.Fuel Filter

5) Remove the fuel pump holder from the fuel filter assembly.

A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Be careful not to spill fuel. • If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain fuel before starting work to avoid the fuel to spill. • Be careful not to drop or apply any impact to the fuel pump during work. This may deteriorate its performance.

FU-05023

6) Remove the fuel pump from the fuel filter assembly.

NOTE: The fuel filter is built in fuel pump assembly. 1) Remove the fuel pump assembly. 2) Remove the fuel level sensor and fuel temperature sensor. 3) Disconnect the connector from the fuel filter assembly.

FU-05074

4) Disengage the claw connecting the fuel filter assembly and fuel chamber assembly, and separate fuel filter assembly and fuel chamber assembly.

FU-05075

FU(H6DO)-73

FU-05024

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Fuel Filter FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 1) Assemble the gasket spacer (A) and support rubber cushion (B) to the fuel pump, and install the fuel pump to the fuel filter assembly.

• Check that the claw connecting the fuel filter assembly and fuel chamber assembly is securely fastened.

NOTE: • Use a new gasket spacer. • Use a new support rubber cushion. • Apply gasoline to the surface of gasket spacer and support rubber cushion.

(B)

(B)

(A) (A)

(A)

FU-03889

FU-05025

2) Install the fuel pump holder to the fuel filter assembly. FU-05075

4) Connect the fuel pump connector.

FU-03886

3) Install the pump module spring (A) to fuel filter assembly, and install the fuel chamber assembly (B). NOTE: • Use a new fuel chamber assembly.

FU-05074

5) Install the fuel level sensor and fuel temperature sensor. 6) Inspect the fuel level sensor. 7) Install the fuel pump assembly.

FU(H6DO)-74

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Fuel Damper FUEL INJECTION (FUEL SYSTEMS)

29.Fuel Damper A: REMOVAL WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. 1) Release the fuel pressure. 2) Disconnect the fuel delivery hose (A) from fuel damper and remove the fuel damper.

(A) (A)

FU-05050

B: INSTALLATION Install in the reverse order of removal. NOTE: If fuel hoses or clamps are damaged, replace them with new parts.

Tightening torque: 1.25 N·m (0.1 kgf-m, 0.9 ft-lb)

C: INSPECTION 1) Check that the fuel damper has no deformation, cracks or other damages. 2) Check the fuel delivery hose for cracks, damage or looseness.

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Fuel Delivery and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

30.Fuel Delivery and Evaporation Lines A: REMOVAL

FU-05078

WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Set the vehicle on a lift. 2) Release the fuel pressure. 3) Open the fuel filler lid and remove the fuel filler cap. 4) Remove the floor mat. 5) In the engine compartment, disconnect the fuel delivery hoses and evaporation hose. CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth.

(1) Remove the connect check cover from the fuel delivery hose.

FU-05079

ST

(2) Install the ST to the fuel pipe. 42099AE000 QUICK CONNECTOR RELEASE (3) Disconnect the quick connector of the fuel delivery hose by pushing the ST in the direction of the arrow.

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Fuel Delivery and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

(4) Remove the clip and disconnect the evaporation hose from the fuel pipe. (D) (C)

ST

(B)

(A)

(A)

FU-05081

(B) FU-05080

(A) Fuel delivery hose (B) Evaporation hose

6) Remove the fuel tank. 7) Remove the rear mud guard LH. 8) Remove the purge hose (A), purge pipe (B), vent hose (C) and drain tube assembly (D).

9) Remove the fuel pipe assembly from vehicle. 10) Disconnect the quick connector, and disconnect the fuel delivery tube and fuel sub delivery tube. (1) Push the retainer in the direction of the arrow, disconnect the quick connector from pipe. NOTE: Clean the pipe and quick connector, if they are covered with dust.

NOTE: Disconnect the quick connector as shown in the figure.

(B)

1 (A)

(C)

2

FU-00124

(A) Quick connector (B) Retainer (C) Pipe 1

(2) To prevent from damaging or entering foreign matter, wrap the pipes and quick connectors with plastic bag etc.

(a) 1 2

(b)

1

EC-02590

(a) Vent hose (C) and drain tube ASSY (D) (b) Purge pipe (B)

FU-01333

11) Remove the evaporation pipe. (1) Remove the rear mud guard RH.

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Fuel Delivery and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

(2) Remove the evaporation hose.

2) Install the evaporation pipe protector.

Tightening torque: T1: 1 N·m (0.1 kgf-m, 0.7 ft-lb) T2: 7.5 N·m (0.7 kgf-m, 5.4 ft-lb) T2

T1

FU-05082

(3) Remove the trunk side trim panel assembly - side on RH. (4) Remove the evaporation pipe protector.

FU-05034

3) Install the trunk side trim panel assembly - side on RH. 4) Install the evaporation hose.

FU-05032

(5) Remove the evaporation pipe from the vehicle. FU-05082

5) Install the rear mud guard RH.

2. CONNECTING THE FUEL LINE QUICK CONNECTOR

FU-05033

CAUTION: Make sure there are no damage or dust on connections. If necessary, clean seal surface of pipe.

B: INSTALLATION Install in the reverse order of removal while being careful of the following.

(A)

1. INSTALLATION OF EVAPORATION PIPE (B)

1) Install the evaporation pipe to the vehicle.

FU-00125

(A) Seal surface (B) Pipe

1) Set the retainer to quick connector. FU-05033

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Fuel Delivery and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

L1: 2.5±1.5 mm (0.098±0.059 in)

NOTE: Use a new retainer. 2) Connect the quick connector to pipe.

L2: 22.5±2.5 mm (0.886±0.098 in) (3) (4) (5)

CAUTION: • Make sure that the quick connector is securely connected.

(6)

(1) L1 L2 (2) L1

FU-04503

(A)

(B)

(1) (2) (3) (4) (5) (6)

(C) FU-00127

(A) Quick connector (B) Retainer (C) Pipe

• Make sure the two retainer pawls are engaged in their mating positions in the quick connector. • Be sure to inspect tubes and their connections for any leakage of fuel.

When there is a spool or stopper When there is no spool or stopper Pipe Spool or stopper Clamp Hose

4. EVAPORATION HOSE CONNECTION Connect the evaporation hose to the pipe with an overlap of 15 to 20 mm (0.59 to 0.79 in).

L = 17.5±2.5 mm (0.689±0.098 in) (2)

(1)

(A)

(3)

(B)

(C) L/2 L FU-04501 FU-00126

(1) Hose (2) Clip (3) Pipe

(A) Quick connector (B) Retainer (C) Pipe

3. CONNECTING THE FUEL DELIVERY HOSE Connect the fuel delivery hose as shown in the figure. CAUTION: • If the connection portion has a spool or stopper, do not allow the end of the hose to bend or ride over by inserting the hose too deep. • Be sure to inspect hoses and their connections for any leakage of fuel.

5. CONNECTING THE EVAPORATION LINE QUICK CONNECTOR CAUTION: • Make sure there are no damage or dust on connections. If necessary, clean the seal surface of the pipe. • Make sure that the quick connector is securely connected.

Tightening torque: 1.25 N·m (0.1 kgf-m, 0.9 ft-lb)

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Fuel Delivery and Evaporation Lines FUEL INJECTION (FUEL SYSTEMS)

Connect the quick connector as shown in the figure.

FU-05035

C: INSPECTION 1) Check that the fuel pipe has no deformation, cracks or other damages. 2) Check that the hose and tube have no cracks, damage or loose part.

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Fuel System Trouble in General FUEL INJECTION (FUEL SYSTEMS)

31.Fuel System Trouble in General A: INSPECTION Trouble

Possible cause a. Fuel pump does not operate. Defective terminal contact

Insufficient fuel supply to injector

Gasoline smell inside of compartment Defective fuel gauge Noise

Inspect contact, especially ground, and tighten it securely.

Trouble in electromagnetic or electronic circuit parts

Replace the faulty parts.

b. Decline of fuel pump function

Replace the fuel pump.

c. Clogged fuel filter

Replace the fuel filter. Clean or replace the fuel tank if necessary.

d. Clogged or bent pipe, hose or tube of fuel line

Clean, correct or replace the pipe, hose or tube of the fuel line.

e. Air is mixed in fuel system.

Leakage or run-out of fuel

Corrective action

f. Damaged diaphragm of pressure regulator a. Loose connection in pipe, hose or tube of fuel line b. Cracks in pipe, hose or tube of fuel line c. Cracks or defective welded part of fuel tank

Check the fuel line connections, and repair or replace the defective part. Replace the pressure regulator. Check the fuel line connections, and repair or replace the defective part. Replace the pipe, hose or tube of the fuel line. Replace the fuel tank.

d. Clogged or bent pipe, hose or tube of fuel line

Clean, correct or replace the pipe, hose or tube of the fuel line.

a. Loose connection in pipe, hose or tube of fuel line b. Improper installation of rubber saucer c. Defective canister

Check the fuel line connections, and repair or replace the defective part. Correct or replace the rubber saucer. Replace the canister.

a. Defective operation of fuel level sensor Replace the fuel level sensor. b. Defective operation of combination meter Replace the combination meter. a. Big operation noise or vibration from fuel pump Replace the fuel pump.

NOTE: • When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank. Fill fuel fully to prevent the problem. • In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop to 0°C (32°F) or less throughout the winter season, use a water removing agent in the fuel system to prevent freezing fuel system and accumulating water. • When water is accumulated in fuel filter, fill the water removing agent in the fuel tank. • Before using water removing agent, follow the cautions noted on the bottle.

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Fuel System Trouble in General FUEL INJECTION (FUEL SYSTEMS)

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EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(H6DO) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Page General Description ...................................................................................2 Front Catalytic Converter ...........................................................................3 Rear Catalytic Converter ............................................................................4 EGR Valve .................................................................................................5 Canister ......................................................................................................6 Purge Control Solenoid Valve ..................................................................10 Fuel Level Sensor ....................................................................................12 Fuel Temperature Sensor ........................................................................13 Fuel Sub Level Sensor .............................................................................14 Fuel Tank Pressure Sensor .....................................................................15 Drain Filter ................................................................................................17 Drain Valve ...............................................................................................18 PCV Valve ................................................................................................19

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General Description EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

1. General Description A: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.

B: PREPARATION TOOL 1. GENERAL TOOL TOOL NAME Circuit tester Mighty Vac

REMARKS Used for measuring resistance. Used for inspection of the two-way valve.

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Front Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

2. Front Catalytic Converter A: REMOVAL The front and rear catalytic converters are integrated into the front exhaust pipe; therefore, refer to “Front Exhaust Pipe” for the removal procedure.

B: INSTALLATION The front and rear catalytic converters are integrated into front exhaust pipe as one unit; therefore, refer to “Front Exhaust Pipe” for installation procedure.

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Check for hole or rust.

EC(H6DO)-3

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Rear Catalytic Converter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converters are integrated into the front exhaust pipe; therefore, refer to “Front Exhaust Pipe” for the removal procedure.

B: INSTALLATION The front and rear catalytic converters are integrated into front exhaust pipe as one unit; therefore, refer to “Front Exhaust Pipe” for installation procedure.

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Check for hole or rust.

EC(H6DO)-4

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EGR Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

4. EGR Valve A: REMOVAL Refer to “EGR Valve” for removal procedure.

B: INSTALLATION Refer to “EGR Valve” for the installation procedure.

C: INSPECTION Refer to “EGR Valve” for inspection procedures.

EC(H6DO)-5

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

5. Canister

5) Remove the clip holding the rear wiring harness.

A: REMOVAL 1) Remove the rear wheel LH. 2) Lift up the vehicle. 3) Remove the rear mud guard LH. 4) Disconnect the quick connectors of the vent tube (A), canister drain tube (B) and charge tube (C), and remove the tubes from clips (D). NOTE: Disconnect the quick connector as shown in the figure.

EC-02608

6) Remove the canister from vehicle.

1 2

1 (a) 1 2

1

(b)

EC-02609 EC-02615

7) Disconnect the connector from drain valve.

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C)

(C) (A)

EC-02610 (B)

(D) EC-02607

8) Disconnect the vent tube (A), canister drain tube (B) and charge tube (C), and remove the canister drain tube (B) from clip (D).

EC(H6DO)-6

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

NOTE: Disconnect the quick connector as shown in the figure. 1

B: INSTALLATION 1) Install the vent tube (A), canister drain tube (B) and charge tube (C), and install the canister drain tube (B) to clip (D). CAUTION: • Make sure there are no damage or dust on connections. If necessary, clean the seal surface of the pipe. • Make sure that the quick connector is securely connected.

2

1 (a) 1 2

(b)

1

EC-02615

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C) (B)

(A)

(C)

(D)

EC-02611

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

NOTE: Connect the quick connector as shown in the figure.

2) Connect the connector to the drain valve.

EC-02610

3) Install the canister to the vehicle.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

(a)

(b)

EC-02616

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C) (B)

(A)

EC-02609

4) Secure the rear wiring harness with clip. (C)

(D)

EC-02608 EC-02611

5) Attach all tubes to clips (D), and connect the quick connectors of the vent tube (A), canister drain tube (B) and charge tube (C).

EC(H6DO)-8

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Canister EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

CAUTION: • Make sure there are no damage or dust on connections. If necessary, clean the seal surface of the pipe. • Make sure that the quick connector is securely connected.

C: INSPECTION 1) Check that the canister has no deformation, cracks or other damages. 2) Check that the tube has no cracks, damage or loose part.

NOTE: Connect the quick connector as shown in the figure.

(a)

(b)

EC-02616

(a) Vent tube (A) and canister drain tube (B) (b) Charge tube (C)

(C) (A)

(B)

(D) EC-02607

6) Install the rear mud guard LH. 7) Lower the vehicle. 8) Install the rear wheel LH.

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb)

EC(H6DO)-9

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Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

6. Purge Control Solenoid Valve

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

1) Remove the collector cover.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

(B)

(A)

EC-02614

(A) To fuel pipe (evaporation line) (B) To intake manifold

(A)

C: INSPECTION (B)

1. PURGE CONTROL SOLENOID VALVE

(B) ME-04447

2) Disconnect the ground cable from battery. 3) Remove the air intake boot assembly. 4) Disconnect the connector and hoses of purge control solenoid valve, and then remove the purge control solenoid valve.

1) Check that the purge control solenoid valve has no deformation, cracks or other damages. 2) Measure the resistance between the purge control solenoid valve terminals.

2 1

EC-02561

EC-02613

Purge control solenoid valve

Terminal No.

Standard

1 and 2

32±3 Ω (when 20°C (68°F))

3) Check that air does not come out from (B) when air is blown into (A).

(B)

(A)

EC-02562

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Purge Control Solenoid Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

4) With terminal No. 1 connected to the battery positive terminal and terminal No. 2 to the battery ground terminal, check that air comes out from (B) when air is blown into (A).

2 1

(B)

(A)

EC-02563

2. OTHER INSPECTIONS Check that the evaporation hose has no cracks, damage or loose part.

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Fuel Level Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

7. Fuel Level Sensor A: REMOVAL For removal procedures, refer to the “FU(H4DOTC)” section.

B: INSTALLATION For installation procedures, refer to the “FU(H4DOTC)” section.

C: INSPECTION For inspection procedures, refer to the “FU(H4DOTC)” section.

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Fuel Temperature Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

8. Fuel Temperature Sensor

C: INSPECTION

A: REMOVAL

1) Check the fuel temperature sensor for deformation, cracks or other damages. 2) Measure the resistance between fuel temperature sensor terminals.

Fuel temperature sensor is integrated with the fuel level sensor. Refer to “Fuel Level Sensor” for removal procedure.

CAUTION: Make sure of the circuit tester spec and do not apply a voltage of 3 V or more when measuring the resistance. Otherwise the fuel temperature sensor will be damaged.

1 2 3 4

(A) EC-02391

(A) Fuel temperature sensor

B: INSTALLATION

EC-02452

Refer to “Fuel Level Sensor” for the installation procedure.

Temperature

Terminal No.

–10°C (14°F) 20°C (68°F) 50°C (122°F)

(A) EC-02391

(A) Fuel temperature sensor

EC(H6DO)-13

Standard 9.2±2.2 kΩ (at a set current of 0.5 mA)

2 and 3

2.5±0.2 kΩ (at a set current of 1.0 mA) 0.84+0.06 –0.05 kΩ (at a set current of 1.0 mA)

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Fuel Sub Level Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

9. Fuel Sub Level Sensor A: REMOVAL For removal procedure, refer to “FU(H6DO)” section.

B: INSTALLATION For installation procedure, refer to “FU(H6DO)” section.

C: INSPECTION For inspection procedures, refer to the “FU(H6DO)” section.

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Fuel Tank Pressure Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

10.Fuel Tank Pressure Sensor

C: INSPECTION

A: REMOVAL

1. FUEL TANK PRESSURE SENSOR

WARNING: Place “NO OPEN FLAMES” signs near the working area. 1) Disconnect the ground cable from battery. 2) Open the fuel filler lid and remove the fuel filler cap. 3) Lift up the vehicle. 4) Disconnect connector (A) from fuel tank pressure sensor. 5) Pull out the vacuum hose (B) from vehicle. 6) Remove the fuel tank pressure sensor from the bracket.

1) Check that the fuel tank pressure sensor does not have deformation, cracks or other damages. 2) Connect dry-cell battery positive terminal to terminal No. 3 and dry-cell battery ground terminal to terminal No. 1, circuit tester positive terminal to terminal No. 2 and the circuit tester negative terminal to terminal No. 1.

(A)

NOTE: • Use new dry-cell batteries. • Using circuit tester, check the voltage of a single dry-cell battery is 1.6 V or more. And also check the voltage of three batteries in series is between 4.8 V and 5.2 V.

3 2 1

(B)

EC-02597

V

7) Disconnect the pressure hose from fuel tank pressure sensor and remove the fuel tank pressure sensor.

1.5V

1.5V

1.5V

4.8 5.2V FU-04486 EC-02598

B: INSTALLATION

3) Check the voltage at a normal atmospheric pressure. NOTE: The atmospheric pressure at higher altitude is lower than normal. Therefore, the voltage is lower than the standard value.

Install in the reverse order of removal.

Tightening torque: 7.35 N·m (0.7 kgf-m, 5.4 ft-lb)

EC-02599

EC(H6DO)-15

Terminal No.

Standard

2 (+) and 1 (–)

Approx. 2.5 V (when 25°C (77°F))

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Fuel Tank Pressure Sensor EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

4) Connect the Mighty Vac to the pressure port (A) on the fuel tank pressure sensor.

(A) EC-02586

5) Check the voltage when generating vacuum and positive pressure using Mighty Vac. CAUTION: Be sure to apply pressure within a range of –10 — 20 kPa (–0.1 — 0.2 kgf/cm2, –1.45 — 2.90 psi). Otherwise the fuel tank pressure sensor will be damaged. Pressure –6.67 kPa (–0.07 kgf/cm2, –0.97 psi) 6.67 kPa (0.07 kgf/cm2, 0.97 psi)

Terminal No.

2 (+) and 1 (–)

Standard Approx. 0.5 V (when 25°C (77°F)) Approx. 4.5 V (when 25°C (77°F))

2. OTHER INSPECTIONS Check that the hose has no cracks, damage or loose part.

EC(H6DO)-16

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Drain Filter EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

11.Drain Filter A: SPECIFICATION Drain valve is a non-disassembled part, so do not remove the drain filter from drain valve. Refer to “Canister” for removal and installation procedures.

EC(H6DO)-17

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Drain Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

12.Drain Valve A: REMOVAL Drain valve is integrated with canister. Refer to “Canister” for removal procedure.

B: INSTALLATION Refer to “Canister” for the installation procedure.

C: INSPECTION Measure the resistance between drain valve terminals.

2 1

EC-02455

Terminal No. 1 and 2

Standard 20 — 30 Ω

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PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

13.PCV Valve

3) Check that air does not come out from (B) when air is blown into (A).

A: REMOVAL 1) Disconnect the PCV hose.

(A)

(B)

EC-02618

EC-02133

2) Remove the PCV valve from rocker cover.

2. OTHER INSPECTIONS Check the vacuum hose for cracks, damage or looseness.

EC-02134

B: INSTALLATION Install in the reverse order of removal. NOTE: Apply liquid gasket to the bolt threads of PCV valve.

Liquid gasket: THREE BOND 1141G or equivalent Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

C: INSPECTION 1. PCV VALVE 1) Check that the PCV valve has no deformation, cracks or other damages. 2) Check that air is discharged from (B) when air is blown into (A).

(B)

(A)

EC-02617

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PCV Valve EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(H6DO)-20

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INTAKE (INDUCTION)

IN(H6DO) 1. 2. 3. 4. 5. 6.

Page General Description ...................................................................................2 Air Cleaner Element ...................................................................................4 Air Cleaner Case ........................................................................................5 Air Intake Boot ............................................................................................7 Air Intake Duct ............................................................................................8 Resonator Chamber ...................................................................................9

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General Description INTAKE (INDUCTION)

1. General Description A: COMPONENT (10)

T1 (10) (11)

(9) T5

(7) (4) T5 (8) (2) T3

T4

(13) (6) (5)

(3)

(1)

T2

(12)

(12)

T2

T4

(15) (14)

IN-02774

IN(H6DO)-2

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General Description INTAKE (INDUCTION) (1) (2) (3)

Air intake duct Clip Resonator chamber

(9) (10) (11)

Air cleaner case (rear) Clip Mass air flow and intake air temperature sensor

(4) (5) (6) (7) (8)

Cushion Spacer Cushion Air cleaner case (front) Air cleaner element

(12) (13) (14) (15)

Clamp Air intake boot ASSY Collector cover bracket Blow-by hose

B: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.

IN(H6DO)-3

Tightening torque:N·m (kgf-m, ft-lb) T1: 1 (0.1, 0.7) T2: 3 (0.3, 2.2) T3: 6 (0.6, 4.4) T4: 6.5 (0.7, 4.8) T5: 7.5 (0.8, 5.5)

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Air Cleaner Element INTAKE (INDUCTION)

2. Air Cleaner Element

6) Pull the air cleaner case (rear) backward of the vehicle, and remove the air cleaner element.

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the power steering oil pressure hose (suction hose) from the clip on the side of air cleaner case (rear).

IN-02757

B: INSTALLATION Install in the reverse order of removal. IN-02762

3) Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B).

CAUTION: Be sure to use SUBARU genuine air cleaner element depending on the engine type when replacing the air cleaner elements. Using other air cleaner element may affect the engine performance. NOTE: • Check that there are no foreign objects in the air cleaner case. • When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install.

(A)

Tightening torque: 3 N·m (0.3 kgf-m, 2.2 ft-lb)

(B) IN-02755

4) Loosen the clamp (A) which connects the air cleaner case (rear) and air intake boot assembly. 5) Remove the clip (B) securing the upper side of air cleaner case.

IN-02758

(A)

C: INSPECTION (B)

IN-02756

1) Check that the air cleaner element has no deformation, cracks or other damages. 2) Check if the air cleaner element is extremely dirty.

IN(H6DO)-4

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Air Cleaner Case INTAKE (INDUCTION)

3. Air Cleaner Case

8) Remove the bolts (A) and nuts (B) which secure the air cleaner case (front) to the body.

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the power steering oil pressure hose (suction hose) from the clip on the side of air cleaner case (rear).

(A)

IN-02762

3) Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B).

(B)

IN-02759

9) Remove the air cleaner case (front).

B: INSTALLATION

(A)

1) Install the bolt (A) and nut (B) which secure the air cleaner case (front) to the body. (B) IN-02755

4) Loosen the clamp (A) which connects the air cleaner case (rear) and air intake boot. 5) Remove the clip (B) securing the upper side of air cleaner case (rear).

Tightening torque: Bolt (A) 6 N·m (0.6 kgf-m, 4.4 ft-lb) Nut (B) 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(A)

(A)

(B)

IN-02756

6) Remove the air intake duct. 7) Remove the air cleaner case (rear) and air cleaner element. (B)

IN-02759

IN(H6DO)-5

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Air Cleaner Case INTAKE (INDUCTION)

2) Install the air cleaner case (rear) and the air cleaner element. NOTE: When installing the air cleaner case (rear), align the protrusion of the air cleaner case (rear) to the hole on the air cleaner case (front) to install. 3) Install the air intake duct. 4) Attach the clip (B) to the air cleaner case (front), and tighten the clamp (A) connecting the air cleaner case (rear) and air intake boot assembly.

C: INSPECTION 1) Check that the air cleaner case has no deformation, cracks or other damages. 2) Check the air intake boot assembly for cracks, damage or looseness.

Tightening torque: Clamp (A) 3 N·m (0.3 kgf-m, 2.2 ft-lb)

(A)

(B)

IN-02756

5) Connect the connector (A) to the mass air flow and intake air temperature sensor, and fasten the harness to clip (B).

(A)

(B) IN-02755

6) Connect the power steering oil pressure hose (suction hose) to the clip on the side of air cleaner case (rear).

IN-02762

7) Connect the ground cable to battery.

IN(H6DO)-6

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Air Intake Boot INTAKE (INDUCTION)

4. Air Intake Boot

B: INSTALLATION

A: REMOVAL

1) Install the air intake boot assembly and connect the blow-by hose. 2) Tighten the clamp (A) which connects the air intake boot assembly and throttle body. 3) Tighten the bolt (B) which secures the air intake boot assembly and collector cover bracket.

1) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

Tightening torque: Clamp (A) 3 N·m (0.3 kgf-m, 2.2 ft-lb) Bolt (B) 6.5 N·m (0.7 kgf-m, 4.8 ft-lb) (B)

(A)

(A)

(B)

(A)

(B) ME-04447

IN-02761

2) Loosen the clamp which connects the air intake boot assembly and air cleaner case (rear).

4) Tighten the clamp which connects the air intake boot assembly and air cleaner case (rear).

Tightening torque: 3 N·m (0.3 kgf-m, 2.2 ft-lb)

IN-02760

3) Loosen the clamp (A) which connects the air intake boot assembly and throttle body. 4) Loosen the bolt (B) which secures the air intake boot assembly and collector cover bracket.

IN-02760

5) Install the collector cover.

C: INSPECTION 1) Check that the air intake boot assembly does not have deformation, cracks or other damages. 2) Check there is no foreign matter in the air intake boot assembly.

(B) (A)

IN-02761

5) Disconnect the blow-by hose and remove the air intake boot assembly.

IN(H6DO)-7

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Air Intake Duct INTAKE (INDUCTION)

5. Air Intake Duct A: REMOVAL 1) Remove the clip securing the air intake duct. 2) Remove the air intake duct.

IN-02660

B: INSTALLATION Install in the reverse order of removal.

C: INSPECTION 1) Check that the air intake duct has no deformation, cracks or other damages. 2) Check that no foreign matter is mixed in air intake duct.

IN(H6DO)-8

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Resonator Chamber INTAKE (INDUCTION)

6. Resonator Chamber A: REMOVAL The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to “Air Cleaner Case” for removal procedure.

B: INSTALLATION The resonator chamber and air cleaner case are integrated into one unit; therefore, refer to “Air Cleaner Case” for installation procedure.

C: INSPECTION Check that the resonator chamber has no deformation, cracks or other damages.

IN(H6DO)-9

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Resonator Chamber INTAKE (INDUCTION)

IN(H6DO)-10

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MECHANICAL

ME(H6DO) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Page General Description ...................................................................................2 Compression ............................................................................................25 Idle Speed ................................................................................................26 Ignition Timing ..........................................................................................27 Intake Manifold Vacuum ...........................................................................28 Engine Oil Pressure .................................................................................29 Fuel Pressure ...........................................................................................30 Valve Clearance .......................................................................................31 Engine Assembly .....................................................................................34 Engine Mounting ......................................................................................43 Preparation for Overhaul ..........................................................................47 V-belt ........................................................................................................48 Crank Pulley .............................................................................................49 Chain Cover .............................................................................................50 Timing Chain Assembly ...........................................................................58 Cam Sprocket ..........................................................................................77 Crank Sprocket ........................................................................................78 Camshaft ..................................................................................................79 Cylinder Head ..........................................................................................86 Cylinder Block ..........................................................................................96 Oil Flow Control Solenoid Valve .............................................................118 Intake and Exhaust Valve ......................................................................119 Piston .....................................................................................................120 Connecting Rod .....................................................................................121 Crankshaft ..............................................................................................122 Engine Trouble in General .....................................................................123 Engine Noise ..........................................................................................129

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General Description MECHANICAL

1. General Description A: SPECIFICATION Model

3.6 L Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine

Cylinder arrangement Valve system mechanism Bore × Stroke Displacement Compression ratio Compression pressure (350 rpm and fully open throttle) Number of piston rings

mm (in) cm3 (cu in) kPa (kgf/cm2, psi) Standard

Intake valve timing Engine

Close

Open Exhaust valve timing Close

Idle speed [“P” or “N” range] Ignition order Ignition timing

1,275 — 1,471 (13.0 — 15.0, 185 — 213) Pressure ring: 2, Oil ring: 1

Open

Valve clearance

Chain driven, double overhead camshaft, 4valve/cylinder 92 × 91 (3.622 × 3.583) 3,629 (221) 10.5

mm (in)

Max. retard Min. advance Max. retard

BTDC 40° ABDC 74°

Min. advance

ABDC 24°

Max. retard

BBDC 4°

Min. advance

BBDC 44°

Max. retard Min. advance

ATDC 44° ATDC 4° 0.20+0.04 –0.06 (0.0079+0.0016 –0.0024)

Intake Exhaust

No load rpm A/C ON

ATDC 10°

0.35±0.05 (0.0138±0.0020) Standard Standard

BTDC/rpm Standard

ME(H6DO)-2

700±100 700 — 910±100 1→6→3→2→5→4 15°±8°/700

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General Description MECHANICAL

NOTE: OS: Oversize US: Undersize Bending limit

Camshaft

Cam lobe height

Intake mm (in) Exhaust

mm (in) Standard Standard

0.020 (0.00079) 45.90 — 46.00 (1.8071 — 1.8110) 44.65 — 44.75 (1.7579 — 1.7618)

Cam base circle diameter

mm (in)

Oil clearance

Intake Exhaust Front mm (in) Except for front mm (in)

Standard Standard Standard Standard Standard

36.00 (1.4173) 36.00 (1.4173) 37.946 — 37.963 (1.4939 — 1.4946) 25.946 — 25.963 (1.0215 — 1.0222) 0.037 — 0.072 (0.0015 — 0.0028)

Thrust clearance

mm (in)

Intake Exhaust

Standard Standard

0.075 — 0.135 (0.0030 — 0.0053) 0.075 — 0.135 (0.0030 — 0.0053)

Journal O.D.

Cylinder head

Valve seat

Warping limit (Mating surface with cylinder block) Standard height Seating angle between valve and valve seat Contacting width of valve and valve seat Clearance between the valve guide and valve stem Inside diameter

Valve guide

Valve

mm (in)

0.020 (0.0008)

mm (in)

124±0.05 (4.88±0.0020) 90°

Intake Exhaust Intake

Standard Standard Standard

1.0 (0.039) 1.5 (0.059) 0.030 — 0.057 (0.0012 — 0.0022)

Exhaust

Standard

0.040 — 0.067 (0.0016 — 0.0026)

mm (in)

5.500 — 5.512 (0.2165 — 0.2170)

Intake Valve stem outer diameter mm (in) Exhaust Intake mm (in) Valve guide protrusion amount Exhaust mm (in) Intake Standard Head edge thickness mm (in) Exhaust Standard Intake Overall length mm (in) Exhaust

5.455 — 5.470 (0.2148 — 0.2154) 5.445 — 5.460 (0.2144 — 0.2150) 8.6 — 9.0 (0.3386 — 0.3543) 10.7 — 11.1 (0.4213 — 0.4370) 1.0 (0.039) 1.2 (0.047) 103.5 (4.075) 103.2 (4.063)

Free length Valve spring

mm (in)

mm (in)

mm (in)

Intake Exhaust

49.06 (1.9315) 49.06 (1.9315) Set

Tension/spring height

N (kgf, lb)/mm (in)

mm (in) Standard mm (in) Standard

316 — 350 (32.2 — 35.7, 71.0 — 78.7) /21.0 (0.827) 2.5°, 2.1 mm (0.083 in) 32.959 — 32.975 (1.2976 — 1.2982) 32.994 — 33.016 (1.2990 — 1.2998)

mm (in) Standard

0.019 — 0.057 (0.0007 — 0.0022)

Lift

Valve lifter

Cylinder block

Squareness Outer diameter Inner diameter of valve lifter mating surface Clearance between valve lifter and valve lifter mating surface

182 — 210 (18.6 — 21.4, 40.9 — 47.2) /31.0 (1.220)

Warping limit mm (in) (Mating surface with cylinder head) Standard height mm (in) Taper mm (in) Standard Out-of-roundness mm (in) Standard Cylinder to piston clearance at mm (in) Standard 20°C (68°F): Cylinder inner diameter boring limit (diameter) mm (in)

ME(H6DO)-3

0.020 (0.0008) 202 (7.95) 0.030 (0.0012) 0.010 (0.0004) –0.010 — 0.010 (–0.0004 — 0.0004) 92.515 (3.6717)

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General Description MECHANICAL Piston grade point

mm (in) A B

Standard Piston

Outer diameter

mm (in)

Inner diameter of piston pin hole

0.25 (0.0098) OS 0.50 (0.0197) OS mm (in) Standard

Standard Standard Standard Standard Standard

Piston pin must be fitted into position with thumb at 20°C (68°F). 21.994 — 22.000 (0.8659 — 0.8661) 0.004 — 0.008 (0.0002 — 0.0003) 0.20 — 0.25 (0.0079 — 0.0098) 0.40 — 0.50 (0.0157 — 0.0197) 0.20 — 0.50 (0.0079 — 0.0197)

Standard Standard Standard

0.040 — 0.080 (0.0016 — 0.0031) 0.030 — 0.070 (0.0012 — 0.0028) 0.065 — 0.165 (0.0026 — 0.0065)

Degree of fit Piston pin

Piston ring

Outer diameter mm (in) Clearance between piston and piston pin mm (in) Top ring Piston ring gap mm (in) Second ring Oil ring Clearance between piston ring and piston ring groove

Connecting rod and connecting rod bearing

Bushing of small end

Top ring mm (in) Second ring Oil ring

Bend or twist per 100 mm (3.94 in) in length

mm (in)

Thrust clearance Oil clearance

mm (in) Standard mm (in) Standard

Bearing size (Thickness at center)

Service limit

Standard 0.03 (0.0012) US mm (in) 0.05 (0.0020) US 0.25 (0.0098) US

Clearance between piston pin and bushing

37.3 (1.4685) 92.005 — 92.015 (3.6222 — 3.6226) 91.995 — 92.005 (3.6218 — 3.6222) 92.245 — 92.265 (3.6317 — 3.6325) 92.495 — 92.515 (3.6415 — 3.6423) 22.000 — 22.006 (0.8661 — 0.8664)

mm (in) Standard

ME(H6DO)-4

0.10 (0.0039 in) 0.070 — 0.330 (0.0028 — 0.0130) 0.016 — 0.043 (0.0006 — 0.0017) 1.489 — 1.505 (0.0586 — 0.0593) 1.507 — 1.515 (0.0593 — 0.0596) 1.517 — 1.525 (0.0597 — 0.0600) 1.617 — 1.625 (0.0637 — 0.0640) 0 — 0.022 (0 — 0.0009)

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General Description MECHANICAL Bending limit Out-of-roundness Cylindricality Grinding limit Out-of-roundness Cylindricality Grinding limit

Crank pin

Crank journal

Crank pin outer diameter

Crankshaft and crankshaft bearing

Crank journal outer diameter

Bearing size (Thickness at center)

Thrust clearance Oil clearance

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

0.035 (0.0014) 0.005 (0.0002) 0.006 (0.0002) 51.734 (2.0368) 0.005 (0.0002) 0.006 (0.0002) 63.742 (2.5095)

Standard 0.03 (0.0012) US mm (in) 0.05 (0.0020) US 0.25 (0.0098) US

51.976 — 52.000 (2.0463 — 2.0472) 51.954 — 51.970 (2.0454 — 2.0461) 51.934 — 51.950 (2.0446 — 2.0453) 51.734 — 51.750 (2.0368 — 2.0374)

#1, #3, #5, #7

Standard 0.03 (0.0012) US 0.05 (0.0020) US 0.25 (0.0098) US

63.992 — 64.016 (2.5194 — 2.5203) 63.962 — 63.978 (2.5182 — 2.5188) 63.942 — 63.958 (2.5174 — 2.5180) 63.742 — 63.758 (2.5095 — 2.5102)

#2, #4, #6

Standard 0.03 (0.0012) US 0.05 (0.0020) US 0.25 (0.0098) US

63.992 — 64.016 (2.5194 — 2.5203) 63.962 — 63.978 (2.5182 — 2.5188) 63.942 — 63.958 (2.5174 — 2.5180) 63.742 — 63.758 (2.5095 — 2.5102)

#1, #3, #5

Standard 0.03 (0.0012) US 0.05 (0.0020) US 0.25 (0.0098) US

1.996 — 2.013 (0.0786 — 0.0793) 2.011 — 2.014 (0.0792 — 0.0793) 2.021 — 2.024 (0.0796 — 0.0797) 2.121 — 2.124 (0.0835 — 0.0836)

Standard 0.03 (0.0012) US 0.05 (0.0020) US 0.25 (0.0098) US Standard 0.03 (0.0012) US #7 0.05 (0.0020) US 0.25 (0.0098) US mm (in) Standard mm (in) Standard

1.996 — 2.013 (0.0786 — 0.0793) 2.015 — 2.018 (0.0793 — 0.0794) 2.025 — 2.028 (0.0797 — 0.0798) 2.125 — 2.128 (0.0837 — 0.0838) 1.992 — 2.009 (0.0784 — 0.0791) 2.011 — 2.014 (0.0792 — 0.0793) 2.021 — 2.024 (0.0796 — 0.0797) 2.121 — 2.124 (0.0835 — 0.0836) 0.030 — 0.115 (0.0012 — 0.0045) 0.010 — 0.030 (0.0004 — 0.0012)

mm (in)

#2, #4, mm (in) #6

ME(H6DO)-5

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General Description MECHANICAL

B: COMPONENT 1. V-BELT

(5) (6)

(4)

(3)

T2

(2)

T3

(7)

T1

T3

(8) (9) (1)

T4

ME-04411

(1) (2)

V-belt Collector cover bracket

(6) (7)

Generator plate A/C compressor stay

(3) (4) (5)

Belt tensioner ASSY Power steering pump bracket Generator

(8) (9)

Idler pulley Idler pulley cover

ME(H6DO)-6

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 20 (2.0, 14.8) T3: 25 (2.5, 18.4) T4: 33 (3.4, 24.3)

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General Description MECHANICAL

2. CHAIN COVER

(6) T1

(6)

T2

(4)

T1 (6)

T5 (5)

(2)

(1)

(3)

T1

(7) T3

T4 T3 ME-04256

(1) (2) (3) (4) (5) (6)

Crank pulley cover O-ring Crank pulley Oil seal Chain cover Bolt

(7)

Front mount

ME(H6DO)-7

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 10 (1.0, 7.4) T3: 25 (2.5, 18.4) T4: 45 (4.6, 33.2) T5: 195 (19.9, 143.8)

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General Description MECHANICAL

3. TIMING CHAIN

(1) (5)

T3 (2)

(6)

(20) T1 (17)

T2

(19)

(15) (23) (9) (13) T2 T2

(22) (10)

T2

T1 (12)

(20)

T2 T2

(14) T4

(21) (11)

(3)

(18)

(23)

(4)

T2 (23) T2 (16)

T3 (7) (8)

ME-04428

ME(H6DO)-8

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General Description MECHANICAL (1) (2) (3) (4) (5) (6) (7) (8)

Intake camshaft (RH) Exhaust camshaft (RH) Intake camshaft (LH) Exhaust camshaft (LH) Intake cam sprocket (RH) Exhaust cam sprocket (RH) Intake cam sprocket (LH) Exhaust cam sprocket (LH)

(11) (12) (13) (14) (15) (16) (17) (18)

Chain tensioner lever (Main) Chain tensioner (Main) Chain tensioner (RH) Timing chain (Main) Timing chain (RH) Timing chain (LH) Chain guide (RH) Chain guide (LH)

(9) (10)

Chain tensioner lever (RH) Chain tensioner lever (LH)

(19) (20)

Chain guide (Main) Chain guide (Between cams)

ME(H6DO)-9

(21) (22) (23)

Idler sprocket Chain tensioner (LH) Chain tensioner lever shaft

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 16 (1.6, 11.8) T3: T4: 120 (12.2, 88.5)

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General Description MECHANICAL

4. CYLINDER HEAD AND CAMSHAFT

T1 (28)

T1 T1

(29)

(26)

(27) (30)

T1 T3

T1

T4

(20)

(17)

(21) (22)

(19)

(23)

(18) (3)

(4)

T2 T1

(24)

(16) T1 (25) T1

T3

(5) (1)

(15) T1

(14) (13)

(11) (10)

(12) (9) (2) (5)

T1 (8)

T4

(31)

(7)

(30)

T1 T2

(29)

T1

(6) T1

T1 ME-03338

ME(H6DO)-10

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General Description MECHANICAL (1)

Cylinder head (RH)

(14)

Intake camshaft (LH)

(27)

(2)

Cylinder head (LH)

(15)

(28)

(3)

Cylinder head gasket (RH)

(16)

(29)

Gasket

(4)

Cylinder head gasket (LH)

(17)

(30)

Gasket

(5) (6)

(18) (19)

(31)

Rocker cover (LH)

(20) (21)

Intake camshaft cap (Rear RH) Intake camshaft cap (Center RH)

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7)

(9) (10)

O-ring Exhaust camshaft position sensor (LH) Front camshaft cap (LH) Exhaust oil flow control solenoid valve (LH) Exhaust camshaft cap (Rear LH) Intake camshaft cap (Rear LH)

Intake oil flow control solenoid valve (LH) Intake camshaft position sensor (LH) Intake camshaft position sensor (RH) Exhaust camshaft (RH) Intake camshaft (RH)

Intake oil flow control solenoid valve (RH) Rocker cover (RH)

(22) (23)

Exhaust camshaft cap (Rear RH) Exhaust camshaft cap (Center RH)

T2: 9.75 (1.0, 7.2) T3: 16 (1.6, 11.8)

(11)

Intake camshaft cap (Center LH)

(24)

Front camshaft cap (RH)

T4:

(12)

Exhaust camshaft cap (Center LH) Exhaust camshaft (LH)

(25)

Exhaust camshaft position sensor (RH) Exhaust oil flow control solenoid valve (RH)

(7) (8)

(13)

(26)

ME(H6DO)-11

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General Description MECHANICAL

5. CYLINDER HEAD AND VALVE ASSEMBLY

(2)

(5)

(3)

(1)

(6)

(8)

(9)

(10)

(11)

(3)

(4)

(4) (5) (7)

(8) (9) (10) (11)

ME-06090

(1) (2) (3) (4)

Intake valve Exhaust valve Valve guide (Intake) Valve guide (Exhaust)

(5) (6) (7) (8)

Valve spring seat Stem seal (Intake) Stem seal (Exhaust) Valve spring

ME(H6DO)-12

(9) (10) (11)

Valve spring retainer Valve collet Valve lifter

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General Description MECHANICAL

6. CYLINDER BLOCK T4

T7

(3)

T5 (5) (2)

(1)

T4 (4)

T6

(19)

(6)

(19)

(15)

(18)

T2

(16)

(8)

(17)

(9)

(9)

(9)

(10)

(10)

(9)

(8)

T4 (13) (7)

(19) (20)

(23)

(14) (19) (21) (19)

(10) (22) (19)

T1

(10)

T1

(10) (10)

T3 (9) (11) (12)

T1

ME-04494

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General Description MECHANICAL (1) (2)

Cylinder block (RH) Cylinder block (LH)

(12) (13)

Oil pan lower Oil pressure switch

(23)

(3) (4) (5) (6) (7) (8) (9) (10)

Oil seal Plug Plug Orifice Oil pan upper Stud bolt O-ring Plug

(14) (15) (16) (17) (18) (19) (20) (21)

Oil pressure switch harness Oil filter Oil cooler connector Oil cooler Hose Clamp Hose Oil cooler pipe

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 17 (1.7, 12.5) T3: 18 (1.8, 13.3) T4: 25 (2.5, 18.4) T5: 37 (3.8, 27.3) T6: 54 (5.5, 39.8) T7:

(11)

Magnet

(22)

Hose

ME(H6DO)-14

Oil level switch

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General Description MECHANICAL

7. CRANKSHAFT AND PISTON

T2

(4)

(7)

(5)

(8)

(6)

T1 (14)

(1)

(19) (10) (12) (2) (7)

(3)

(13)

(9) (11)

(8)

(12) (11)

(12)

(9) (7)

(15)

(8)

(12) (10) (18) (16)

(17)

(14) (19)

(17) (16)

(7)

T1

(17)

(6)

(8)

(5) (4)

(16)

ME-06091

(1) (2) (3) (4) (5) (6) (7)

Reinforcement Drive plate Crankshaft sensor plate Top ring Second ring Oil ring Circlip

(9) (10) (11) (12) (13) (14) (15)

Piston Piston pin Connecting rod Connecting rod bearing Crankshaft Connecting rod cap Woodruff key

(8)

Snap ring

(16)

Crankshaft bearing #1, #3, #5

ME(H6DO)-15

(17) (18) (19)

Crankshaft bearing #2, #4, #6 Crankshaft bearing #7 Connecting rod cap bolt

Tightening torque:N·m (kgf-m, ft-lb) T1: 60 (6.1, 44.3) T2:

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General Description MECHANICAL

8. ENGINE HARNESS Engine harness assembly diagram 1 (18) 10

(2)

(20)

(19)

1

(1)

11

2 (3)

9

(4)

(17)

3 (16) (5) 3

(A) (6)

(15) (14)

3

3

(7) (13) (12)

(11)

7

4

(10) 6

8 (21)

(9)

5

(8)

(22) 12

(23)

(B)

(25)

14 (24)

13 ME-04534

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General Description MECHANICAL (A)

Cylinder block upper face

(B)

Intake manifold back surface

(1)

Crankshaft position sensor connector Engine ground

(10)

Knock sensor LH connector

(19)

(11)

Power steering switch connector

(20)

(3)

Intake camshaft position sensor LH connector

(12)

Knock sensor RH connector

(21)

(4)

#6 injector connector

(13)

Intake oil flow control solenoid valve RH connector

(22)

(5)

#4 injector connector

(14)

#1 injector connector

(23)

(6)

#2 injector connector

(15)

#3 injector connector

(24)

(7)

Intake oil flow control solenoid valve LH connector Oil temperature sensor connector

(16)

#5 injector connector

(25)

(17)

Intake camshaft position sensor RH connector Engine harness docking connector

(2)

(8) (9)

Engine coolant temperature sensor connector

(18)

Upper/lower connection connector (To intake manifold) Electronic throttle control connector (To intake manifold) Electronic throttle control connector (From upper part of the cylinder block) Upper/lower connection connector (From upper part of the cylinder block) Purge control solenoid valve connector Manifold absolute pressure sensor connector EGR valve connector

*1: Install so that engine ground terminals face the rear side of vehicle. *2: Route under the heater pipe. *3: Attach the engine harness fixing clip to the fuel pipe stay. *4: Route from the cutout portion on the fuel pipe protector LH. *5: Be careful not to mix up the connectors of oil temperature sensor and engine coolant temperature sensor. *6: Route between crankshaft position sensor and knock sensor LH. *7: Route under the heater pipe. *8: Route under the heater pipe. *9: Route under the fuel pipe. *10: Attach the engine harness fixing clip to the fixing boss on the cylinder block. *11: Route over the heater pipe stay. *12: Securely install the engine harness fixing stay. *13: Route outside the fuel pipe. *14: Attach the engine harness fixing clip to the fixing stay on the intake manifold.

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General Description MECHANICAL

Engine harness assembly diagram 2

(B)

(A)

1 1 (11) (6)

(1)

(10) (7)

2

(3) (9)

(8)

(5)

2

(4)

(2)

ME-04149

(A)

Right side of the engine

(B)

Left side of the engine

(1)

#6 ignition coil connector

(5)

(2) (3)

#4 ignition coil connector Exhaust oil flow control valve solenoid LH connector #2 ignition coil connector

(6) (7)

Exhaust camshaft position sensor LH connector #1 injector connector Exhaust camshaft position sensor RH connector Oil pressure switch connector

(4)

(8)

(9) (10) (11)

Exhaust oil flow control valve solenoid RH connector #3 ignition coil connector #5 ignition coil connector

*1: Align the engine harness stay end with the end of engine harness identification tape. *2: Attach the engine harness fixing clip to the fixing boss on the rocker cover.

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General Description MECHANICAL

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. • All parts should be thoroughly cleaned, paying special attention to engine oil passages, pistons and bearings. • Before applying liquid gasket, completely remove the old liquid gasket and degrease it. • Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly. • All removed parts, if to be reused, should be reinstalled in the original positions and directions. • Bolts, nuts and washers should be replaced with new parts as required. • Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks. • Remove or install the engine in an area where chain hoists, lifting devices, etc. are available for ready use. • Be sure not to damage coated surfaces of body panels with tools, or not to stain seats and windows with coolant or oil. Place a cover over fender, as required, for protection. • Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc. • Lift up or lower the vehicle when necessary. Make sure to support the correct positions.

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 18250AA010

DESCRIPTION CYLINDER HEAD TABLE

REMARKS • Used for replacing valve guides. • Used for removing and installing valve spring.

18232AA000

ENGINE STAND

Used for disassembling and assembling engine.

ST18250AA010

ST18232AA000

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 498497100

DESCRIPTION CRANKSHAFT STOPPER

REMARKS Used for stopping rotation of drive plate when removing/tightening crank pulley bolt.

398744300

PISTON GUIDE

Used for installing piston in cylinder.

499585500

VALVE OIL SEAL GUIDE

Used for press-fitting of intake and exhaust valve guide oil seals.

18350AA000

CONNECTING ROD BUSHING REMOVER AND INSTALLER

Used for removing and installing connecting rod bushing.

CAM SPROCKET WRENCH

Used for removing and installing cam sprocket.

ST-498497100

ST-398744300

ST-499585500

ST18350AA000

499977500

ST-499977500

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 499587200

DESCRIPTION CRANKSHAFT OIL SEAL INSTALLER

REMARKS • Used for installing crankshaft oil seal. • Used together with CRANKSHAFT OIL SEAL GUIDE (499597100).

ST-499587200

499597100

CRANKSHAFT • Used for installing crankshaft oil seal. OIL SEAL GUIDE • Used together with CRANKSHAFT OIL SEAL INSTALLER (499587200).

499718000

VALVE SPRING REMOVER

Used for removing and installing valve spring.

499765700

VALVE GUIDE REMOVER

Used for removing valve guides.

499765900

VALVE GUIDE REAMER

Used for reaming valve guides.

ST-499597100

ST-499718000

ST-499765700

ST-499765900

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 18252AA000

DESCRIPTION CRANKSHAFT SOCKET

REMARKS Used for rotating crankshaft.

1B022XU0

SUBARU SELECT MONITOR III KIT

Used for troubleshooting the electrical system.

498277200

STOPPER SET

Used for installing automatic transmission assembly to engine.

499585700

OIL SEAL GUIDE Used for installing the chain cover oil seal.

ST18252AA000

ST1B022XU0

ST-498277200

ST-499585700

18251AA050

VALVE GUIDE ADJUSTER

ST18251AA050

ME(H6DO)-22

Used for installing valve guides on intake side.

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 18251AA060

DESCRIPTION VALVE GUIDE ADJUSTER

REMARKS Used for installing valve guides on exhaust side.

18355AA000

PULLEY WRENCH

• Used for stopping rotation of crank pulley when removing and installing crank pulley bolt. • Used for stopping rotation of idler sprocket when removing and installing idler sprocket bolt. • Used together with PULLEY WRENCH PIN SET (18334AA000).

18334AA000

PULLEY WRENCH PIN SET

• Used for stopping rotation of crank pulley when removing and installing crank pulley bolt. • Used for stopping rotation of idler sprocket when removing and installing idler sprocket bolt. • Used together with PULLEY WRENCH (18355AA000).

18332AA020

OIL FILTER WRENCH

Used for removing and installing oil filter.

42099AE000

QUICK CONNECTOR RELEASE

Used for disconnecting quick connector of the engine compartment.

ST18251AA060

ST18355AA000

ST18334AA000

ST18332AA020

ST42099AE000

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General Description MECHANICAL ILLUSTRATION

TOOL NUMBER 18360AA020 (Newly adopted tool)

DESCRIPTION HANGER

REMARKS Used for hanging the engine.

ST18360AA020

2. GENERAL TOOL TOOL NAME Compression gauge Timing light Vacuum gauge Oil pressure gauge Fuel pressure gauge TORX ® socket (E12)

REMARKS Used for measuring compression. Used for measuring ignition timing. Used for measuring intake manifold vacuum. Used for measuring engine oil pressure. Used for measuring fuel pressure. Used for removing and installing connecting rod cap.

E: PROCEDURE It is possible to conduct the following service procedures with engine on vehicle, however, the procedures described in this section are based on the condition that the engine is removed from vehicle. • V-belt • Timing chain

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Compression MECHANICAL

2. Compression A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

NOTE: When using a screw-in type compression gauge, the screw should be less than 18 mm (0.71 in) long. 12) Crank the engine by the starter motor, and read the maximum value on the gauge when the needle of gauge is steady. NOTE: • Perform at least two measurements per cylinder, and make sure that the values are correct. • If the compression pressure is out of standard, check or adjust the pistons, valves and cylinders.

(A)

(B)

5) Start the engine and run it until it stalls. 6) After the engine stalls, crank it for five more seconds. 7) Turn the ignition switch to OFF. 8) Remove all spark plugs. 9) Fully open the throttle valve. 10) Check the starter motor for satisfactory performance and operation. 11) Secure the compression gauge tightly against the spark plug hole.

(B) ME-04447

2) After warming-up the engine, turn the ignition switch to OFF. 3) Make sure that the battery is fully charged. 4) Remove the fuse of fuel pump from main fuse box.

Compression (350 rpm and fully open throttle): Standard 1,275 — 1,471 kPa (13.0 — 15.0 kgf/cm2, 185 — 213 psi) Service limit 1,128 kPa (11.5 kgf/cm2, 164 psi) Difference between cylinders 49 kPa (0.5 kgf/cm2, 7 psi) or less 13) After inspection, install the related parts in the reverse order of removal.

(A) FU-04680

(A) Front side

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Idle Speed MECHANICAL

3. Idle Speed A: INSPECTION 1) Before checking the idle speed, check the following item: (1) Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the engine idle speed using Subaru Select Monitor. NOTE: • Idle speed cannot be adjusted manually, because the idle speed is automatically adjusted. • If idle speed is out of standard, refer to the General Diagnosis Table under “Engine Control System”. (1) Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C and etc. are OFF)

Idle speed (No load and gears in “P” or “N” range): Standard 700±100 rpm (2) Check the idle speed when loaded. (Turn the A/C switch to “ON” and operate the compressor for at least one minute before measurement.) Idle speed (A/C ON and gear in “P” or “N” range): Standard 700 — 910±100 rpm

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Ignition Timing MECHANICAL

4. Ignition Timing

(2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

A: INSPECTION CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself at measurement.

(A)

1. METHOD WITH SUBARU SELECT MONITOR 1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Read the ignition timing using Subaru Select Monitor. NOTE: If ignition timing is out of standard, check the ignition control system. Refer to “Engine Control System”.

Ignition timing [BTDC/rpm]: Standard 15°±8°/700

2. METHOD WITH TIMING LIGHT 1) Before checking the ignition timing, check the following item: (1) Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly. (2) Check the malfunction indicator light does not illuminate. 2) Warm up the engine. 3) Stop the engine, and turn the ignition switch to OFF. 4) Remove the collector cover.

(A)

(B)

(B) ME-04447

5) Disconnect the ground cable from battery. 6) Remove the air intake duct. 7) Disconnect the connector from mass air flow and intake air temperature sensor. 8) Remove the air cleaner case and element. 9) Connect the timing light to the power wire of #1 ignition coil. 10) Install the connectors of air cleaner case, element, and the mass air flow and intake air temperature sensor. 11) Connect the ground cable to battery. 12) Start the engine, turn the timing light to the crank pulley, and check the ignition timing through the chain cover gauge. NOTE: If ignition timing is out of standard, check the ignition control system. Refer to “Engine Control System”.

Ignition timing [BTDC/rpm]: Standard 15°±8°/700

30 20

NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A).

10 0 ME-04493

13) After inspection, install the related parts in the reverse order of removal.

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Intake Manifold Vacuum MECHANICAL

5. Intake Manifold Vacuum

3) Remove the air intake boot. 4) Disconnect the brake booster vacuum hose from the intake manifold, and attach the vacuum gauge.

A: INSPECTION 1) Warm up the engine. 2) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

ME-04403

(A)

5) Install the air intake boot. 6) Keep the engine at idle speed and read the vacuum gauge indication.

(A)

(B)

NOTE: Condition of engine inside can be diagnosed by observing the behavior of the vacuum gauge needle as described in table below.

(B) ME-04447

Intake manifold vacuum (at idling, A/C OFF): Standard Less than –60.0 kPa (–450 mmHg, –17.72 inHg)

Diagnosis of engine condition by measurement of intake manifold vacuum Vacuum gauge indication Possible engine condition 1. Needle is steady but lower than standard value. This tenLeakage around intake manifold gasket, disconnection or damdency becomes more evident as engine temperature rises. age of vacuum hose 2. Needle intermittently drops to position lower than standard Leakage around cylinder value. 3. Needle drops suddenly and intermittently from standard Sticky valve value. 4. When engine speed is gradually increased, needle begins to Weak or broken valve springs vibrate rapidly at certain speed, and then vibration increases as engine speed increases. 5. Needle vibrates above and below standard value in narrow Defective ignition system range.

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Engine Oil Pressure MECHANICAL

6. Engine Oil Pressure A: INSPECTION 1) Disconnect the ground cable from battery. 2) Remove the oil pressure switch from the oil pan upper. 3) Attach the oil pressure gauge to the oil pan upper. 4) Connect the ground cable to battery. 5) Start the engine, and measure the oil pressure. NOTE: • If the oil pressure is out of specification, check oil pump, oil filter and lubrication line. • If the oil pressure warning light is ON and oil pressure is within specification, check the oil pressure switch.

Engine oil pressure (at oil temperature of 80°C (176°F)): Standard 100 kPa (1.0 kgf/cm2, 15 psi) or more (at 700 rpm) 500 kPa (5.1 kgf/cm2, 73 psi) or more (at 5,000 rpm) 6) After inspection, install the related parts in the reverse order of removal.

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Fuel Pressure MECHANICAL

7. Fuel Pressure

• Check or replace the fuel pump and fuel delivery line if the fuel pressure is out of the standard.

A: INSPECTION CAUTION: • Before removing the fuel pressure gauge, release the fuel pressure. • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth. 1) Remove the collector cover.

Fuel pressure: Standard 340 — 400 kPa (3.5 — 4.1 kgf/cm2, 49 — 58 psi) 7) After inspection, install the related parts in the reverse order of removal.

NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

(A)

(B)

(B) ME-04447

2) Release the fuel pressure. 3) Open the fuel filler lid and remove the fuel filler cap. 4) Disconnect the fuel delivery hose from the fuel damper, and connect the fuel pressure gauge.

ME-04410

5) Start the engine. 6) Measure the fuel pressure after warming up the engine. NOTE: • The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations.

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Valve Clearance MECHANICAL

8. Valve Clearance A: INSPECTION CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. NOTE: Inspection of valve clearance should be performed while engine is cold. 1) Remove the collector cover.

(3) Disconnect the connector of oil pressure switch. (4) Remove the ignition coil. (5) Remove the rocker cover (RH). 7) When inspecting #2, #4 and #6 cylinders (1) Disconnect the battery cable, and then remove the battery and battery carrier. (2) Remove two fixing clips on the fuel pipe protector (LH).

NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle. ME-04398

(A)

(3) Generator connector (4) Generator terminal B (5) Remove the harness cover from collector cover bracket. (6) A/C compressor solenoid connector (7) Flow sensor connector

(A)

(B)

(B)

(A)

ME-04447

2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Remove the under cover. 5) Lower the vehicle. 6) When inspecting #1, #3 and #5 cylinders (1) Remove the air intake duct, air cleaner case and air intake boot assembly. (2) Remove the fuel pipe protector (RH).

(B)

(E)

(C)

(D)

ME-04399

(A) (B) (C) (D) (E)

Generator connector Terminal B Harness cover A/C compressor solenoid connector Flow sensor connector

(8) Slide the harness and connector to the battery side.

FU-02119

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Valve Clearance MECHANICAL

(9) Disconnect the PCV hose and blow-by hose from the rocker cover (LH).

9) Measure the clearance of intake valve and exhaust valve using thickness gauge (A). NOTE: • Measure it within the range of ±30° from specified position shown in the figure. • Insert a thickness gauge in a direction as horizontal as possible with respect to the valve lifter.

ME-00460

(10) Remove the fuel pipe protector (LH).

Valve clearance (inspection value): Intake 0.20+0.04 –0.06 mm (0.0079+0.0016 –0.0024 in) Exhaust 0.35±0.05 mm (0.0138±0.0020 in) • If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on.

(A)

FU-05137

(11) Remove the ignition coil. (12) Remove the rocker cover (LH). 8) Turn the crankshaft clockwise until the camshaft is set to position shown in the figure. RH

LH

(23˚)

(23˚)

ME-00464

10) If necessary, adjust the valve clearance. 11) Further turn the crank pulley clockwise and then measure the valve clearances again. 12) After inspection, install the related parts in the reverse order of removal.

B: ADJUSTMENT 1. INTAKE SIDE

(1)

(1)

(2)

(2)

(23˚)

(23˚)

ME-03394

(1) Valve clearance (Intake side) (2) Valve clearance (Exhaust side)

CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. NOTE: Adjustment of valve clearance should be performed while engine is cold. 1) Measure all the valve clearances. NOTE: Record each valve clearance after measurement. 2) Remove the timing chain assembly. 3) Remove the cam sprocket.

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Valve Clearance MECHANICAL

4) Remove the camshaft. 5) Remove the valve lifter. 6) Measure the thickness of valve lifter using micrometer.

NOTE: Record each valve clearance after measurement. 2) Remove the camshaft. 3) Remove the valve lifter. 4) Measure the thickness of valve lifter using micrometer.

ME-00025

7) Select a valve lifter of suitable thickness using the measured valve clearance and valve lifter thickness, and install it. NOTE: Use a new valve lifter. Unit: mm (in) S = (V + T) – 0.20 (0.0079) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used

ME-00025

5) Select a valve lifter of suitable thickness using the measured valve clearance and valve lifter thickness, and install it. NOTE: Use a new valve lifter. Unit: mm (in)

8) Install the camshaft. 9) Install the cam sprocket. 10) Install the timing chain assembly. 11) Measure all valve clearance again at this time. If the valve clearance is not correct, repeat the procedure over again from the first step.

Valve clearance (adjustment value): 0.20+0.04 –0.06 mm (0.0079+0.0016 –0.0024 in) 12) After measuring, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket.

S = (V + T) – 0.35 (0.0138) S: Valve lifter thickness required V: Measured valve clearance T: Valve lifter thickness to be used

6) Install the camshaft. 7) Install the cam sprocket. 8) Install the timing chain assembly. 9) Measure all valve clearance again at this time. If the valve clearance is not correct, repeat the procedure over again from the first step.

Valve clearance (adjustment value): 0.35±0.05 mm (0.0138±0.0020 in) 10) After measuring, install the related parts in the reverse order of removal. NOTE: Use a new rocker cover gasket.

2. EXHAUST SIDE CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire. NOTE: Adjustment of valve clearance should be performed while engine is cold. 1) Measure all the valve clearances.

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Engine Assembly MECHANICAL

9. Engine Assembly

(1) Remove two fixing clips on the fuel pipe protector (LH).

A: REMOVAL 1) Change the front hood damper bolt mounting position from (A) to (B), and completely open the front hood.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(A) ME-04398

(B)

(B)

ME-04396

(2) Generator connector (3) Generator terminal B (4) Remove the harness cover from collector cover bracket. (5) A/C compressor solenoid connector (6) Flow sensor connector (A)

2) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

(E)

(C)

(A) (B) (C) (D) (E)

(B) ME-04447

3) Collect the refrigerant from A/C system. 4) Release the fuel pressure. 5) Disconnect the ground cable from battery. 6) Open the fuel filler lid and remove the fuel filler cap. 7) Remove the air intake duct, air cleaner case and air intake boot assembly. 8) Remove the V-belts. 9) Disconnect the following connector.

(D)

ME-04399

(A)

(B)

(B)

Generator connector Terminal B Harness cover A/C compressor solenoid connector Flow sensor connector

(7) Slide the harness and connector to the battery side. 10) Remove the power steering pump together with the bracket. NOTE: Do not disconnect the hose and pipe from the power steering pump.

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Engine Assembly MECHANICAL

(1) Disconnect the manifold absolute pressure sensor connector (A) and power steering pump connector (B).

11) Remove the brake booster vacuum hose.

(A)

(B)

ME-04403 ME-04400

12) Remove the engine ground.

(2) Remove the securing bolts of collector cover bracket and power steering pump bracket.

ME-04404

13) Remove the starter harness and engine ground from bracket.

ME-04405 ME-04401

(3) Use a cloth to protect the power steering pump and place it on the RH front strut using a wire.

14) Remove the starter. 15) Remove the grille bracket. NOTE: Remove ten clips when removing the grille bracket.

ME-04402 CO-02594

16) Lift up the vehicle. 17) Remove the under cover.

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Engine Assembly MECHANICAL

18) Drain engine coolant completely. 19) Remove the front exhaust pipe. 20) Remove the ground cable from the underside of chain cover.

25) Remove the heater inlet hose and heater outlet hose.

ME-04279

26) Disconnect the engine harness connector.

ME-04281

ME-04397

27) Disconnect the connector from the throttle body. ME-04282

21) Remove the connecting bolts and nuts (lower side) between the engine and transmission.

ME-04268

28) Remove the engine harness connector from the engine hanger bracket. AT-04981

22) Lower the vehicle. 23) Remove the radiator main fan & fan motor and radiator sub fan & fan motor. 24) Remove the radiator.

ME(H6DO)-36

ME-04407

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Engine Assembly MECHANICAL

29) Remove the engine hanger bracket.

(1) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose. ST 42099AE000 QUICK CONNECTOR RELEASE

ST

ME-04269

30) Remove the throttle body from the intake manifold. NOTE: Do not disconnect the inlet and outlet hoses of engine coolant. 31) Attach the ST. ST 18360AA020 HANGER

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

ME-04481

(2) Remove the clip and disconnect the evaporation hose. 34) Disconnect the A/C pressure hoses from A/C compressor. 35) Remove the connecting bolts (upper side) between engine and transmission.

ST

ME-04408

32) Separate the torque converter clutch from drive plate. (1) Remove the service hole plug.

AT-04980

36) Set the ST to torque converter clutch case. ST 498277200 STOPPER SET

ST ME-04284

(2) Rotate the clank pulley to align the drive plate to the service hole, and remove four bolts. 33) Disconnect the fuel delivery hose and evaporation hose. CAUTION: • Be careful not to spill fuel. • Catch the fuel from hoses using a container or cloth.

ME(H6DO)-37

ME-00492

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Engine Assembly MECHANICAL

37) Support the engine with a lifting device and wire ropes.

ME-04468

B: INSTALLATION 1) Install the engine to the vehicle. (1) Operate the lifter to place the engine in the engine compartment. (2) Operate the lifter to set the engine horizontally. (3) Move the engine towards the rear of the vehicle to connect it to the torque converter clutch case. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

38) Remove the front mount.

ME-04468 ME-04271

39) Remove the front mounting bracket from the cradle.

2) Install front mounting bracket to the cradle.

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb)

ME-04272

40) Remove the engine from the engine compartment. (1) Operate the lifter to set the engine horizontally. (2) Move the engine towards the front of the vehicle to disconnect it from the torque converter clutch case. (3) Operate the lifter to take out the engine from the engine compartment.

ME-04272

3) Install the front mount.

Tightening torque: T1: 25 N·m (2.5 kgf-m, 18.4 ft-lb) T2: 45 N·m (4.6 kgf-m, 33.2 ft-lb) T1

T2

NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

ME-04273

4) Install the connecting bolts (upper side) between engine and transmission.

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Engine Assembly MECHANICAL

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

NOTE: Make sure there are no gaps in the mating surfaces between engine and transmission. If there are gaps, loosen the connecting bolts, and adjust the position while retightening the bolts.

ME-04281

AT-04980

5) Remove the lifting device and wire ropes. 6) Remove the ST from torque converter clutch case. NOTE: Be careful not to drop the ST into the torque converter clutch case when removing the ST. 7) Install the radiator. 8) Install the radiator main fan & fan motor and radiator sub fan & fan motor. 9) Lift up the vehicle. 10) Attach the connecting bolts and nuts (lower side) between the engine and transmission.

ME-04282

12) Install the front exhaust pipe. 13) Install the under cover. 14) Lower the vehicle. 15) Install the A/C pressure hoses to A/C compressor. 16) Connect the fuel delivery hose (A) and evaporation hose (B). NOTE: If fuel hoses or clamps are damaged, replace them with new parts.

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

(B) (A) AT-04981

11) Install the ground cable to the underside of chain cover.

ME-04483

17) Connect the torque converter clutch to the drive plate. (1) Rotate the clank pulley to align the drive plate to the service hole, and tighten four bolts.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

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Engine Assembly MECHANICAL

(2) Install the service hole plug.

22) Connect the connector to the throttle body.

ME-04284

18) Remove the ST.

ME-04406

23) Connect the engine harness.

ST

ME-04408

19) Install the throttle body to intake manifold. NOTE: Use a new gasket.

ME-04397

24) Install the heater inlet hose and heater outlet hose.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb) 20) Install the engine hanger bracket. Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

ME-04279

25) Attach the grille bracket.

ME-04269

21) Install the engine harness connector to the engine hanger bracket. CO-02594

26) Install the starter.

ME-04407

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Engine Assembly MECHANICAL

27) Install the starter harness and engine ground to the bracket.

Tightening torque: T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) T2: 25 N·m (2.5 kgf-m, 18.4 ft-lb) T3: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

T2 T1 ME-04405

T3

28) Install the engine ground.

T3 T3

ME-04404

29) Install the brake booster vacuum hose.

ME-04446

(3) Connect the manifold absolute pressure sensor connector (A) and power steering pump connector (B). (A)

(B) ME-04403

30) Install the power steering pump together with the bracket. (1) Install the power steering pump and power steering pump bracket to the cylinder block. (2) Install the collector cover bracket and power steering pump bracket.

ME-04400

31) Connect the following connectors. (1) Generator connector (2) Generator terminal B

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb) (3) Install the harness cover to the collector cover bracket. (4) A/C compressor solenoid connector

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Engine Assembly MECHANICAL

(5) Flow sensor connector (A)

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb)

(B)

(A)

(E)

(B) (C)

(A)

(B)

(D)

ME-04399

(A) Generator connector (B) Generator terminal B (C) Install the harness cover to the collector cover bracket. (D) A/C compressor solenoid connector (E) Flow sensor connector

(6) Install with the securing clips to the two locations on the fuel pipe protector (LH).

ME-04396

C: INSPECTION 1) Check that the pipes, hoses, connectors and clips are securely connected. 2) Check that the engine coolant is up to specified level. 3) Check that the ATF is up to specified level. 4) Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise and vibrations.

ME-04398

32) Install the V-belts. 33) Install the air intake duct, air cleaner case and air intake boot assembly.

34) Connect the ground cable to battery. 35) Fill engine coolant. 36) Charge the A/C system with refrigerant. 37) Check the ATF level and replenish it if necessary. 38) Install the collector cover. 39) Change the front hood damper bolt mounting position from (B) to (A), and completely close the front hood.

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Engine Mounting MECHANICAL

10.Engine Mounting

NOTE: Remove ten clips when removing the grille bracket.

A: REMOVAL 1) Change the front hood damper bolt mounting position from (A) to (B), and completely open the front hood.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(A) CO-02594

(B)

(B)

ME-04396

2) Remove the collector cover. NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

5) Lift up the vehicle. 6) Remove the under cover. 7) Drain engine coolant completely. 8) Lower the vehicle. 9) Remove the radiator main fan & fan motor and radiator sub fan & fan motor. 10) Disconnect the engine harness.

(A) ME-04397

(B)

11) Disconnect the connector from the throttle body.

(B) ME-04447

3) Remove the air intake duct, air cleaner case and air intake boot assembly. 4) Remove the grille bracket.

ME-04268

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Engine Mounting MECHANICAL

12) Remove the engine harness connector from the engine hanger bracket.

16) Support the engine with a lifting device and wire ropes.

ME-04407

13) Remove the engine hanger bracket.

ME-04330

17) Remove the front mount.

ME-04269

14) Remove the throttle body from the intake manifold.

ME-04441

18) Remove the front mounting bracket from the cradle.

NOTE: Do not disconnect the inlet and outlet hoses of engine coolant. 15) Attach the ST. ST 18360AA020 HANGER

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) ME-04442 ST

B: INSTALLATION 1) Install front mounting bracket to the cradle.

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb) ME-04408

ME-04442

2) Install the front mount.

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Engine Mounting MECHANICAL

Tightening torque: T1: 25 N·m (2.5 kgf-m, 18.4 ft-lb) T2: 45 N·m (4.6 kgf-m, 33.2 ft-lb)

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

T1

T2

ME-04269 ME-04443

3) Remove the lifting device and wire ropes.

11) Install the engine harness connector to the engine hanger bracket.

ME-04407

ME-04468

4) Install the radiator main fan & fan motor and radiator sub fan & fan motor. 5) Lift up the vehicle. 6) Install the under cover. 7) Lower the vehicle. 8) Remove the ST.

12) Connect the connector to the throttle body.

ME-04268

13) Connect the engine harness. ST

ME-04408

9) Install the throttle body to intake manifold. NOTE: Use a new gasket.

ME-04397

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb) 10) Install the engine hanger bracket.

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Engine Mounting MECHANICAL

14) Attach the grille bracket.

CO-02594

15) Install the air intake duct, air cleaner case and air intake boot assembly.

16) Connect the ground cable to battery. 17) Fill engine coolant. 18) Install the collector cover. 19) Change the front hood damper bolt mounting position from (B) to (A), and completely close the front hood.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(B)

(A)

(B)

ME-04396

C: INSPECTION Check that the front mount and front mount bracket have no deformation, cracks and other damages.

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Preparation for Overhaul MECHANICAL

11.Preparation for Overhaul A: REMOVAL 1) Remove the engine assembly from the body.

2) Set the engine on ST. ST 18232AA000 ENGINE STAND

ST

ME-02448

3) Before servicing overhaul, remove the sensor, pipe and hose that installed to engine. (1) Remove the intake manifold. (2) Remove the generator. (3) Remove the A/C compressor. (4) Disconnect the water pipe and hose. (5) Disconnect the engine harness. (6) Remove the spark plug. (7) Remove the camshaft position sensor.

(8) Remove the crankshaft position sensor.

(9) Remove the knock sensor. (10) Remove the engine coolant temperature sensor. (11) Remove the oil temperature sensor. (12) Remove the oil flow control solenoid valve.

(13) Remove the oil pressure switch. (14) Remove the oil filter. (15) Remove the oil cooler.

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V-belt MECHANICAL

12.V-belt

B: INSTALLATION

A: REMOVAL

Install in the reverse order of removal.

NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the collector cover.

(4)

NOTE: Follow these procedures for removal of the collector cover. (1) Lift up the rear side holding two positions (A). (2) Lift up the front side holding two positions (B) while moving it in the forward direction of the vehicle.

(A)

(6)

(1)

(5)

(2) (3)

(1) (2) (3) (4) (5) (6)

(A)

ME-00474

Power steering oil pump pulley Belt tension adjuster ASSY Crank pulley A/C compressor pulley Belt idler Generator

C: INSPECTION (B)

(B) ME-04447

1) Replace the V-belt, if cracks, fraying or wear is found. 2) Make sure that the V-belt automatic belt tension indicator (A) is within the range (D).

2) Remove the air intake duct. 3) Install the tool to the pulley bolt of the belt tension adjuster assembly. 4) Rotate the tool clockwise and loosen the V-belt to remove.

(A)

(D)

(C) (B)

ME-03362

ME-00475

(A) (B) (C) (D)

ME(H6DO)-48

Indicator Generator Power steering oil pump pulley Service limit

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Crank Pulley MECHANICAL

13.Crank Pulley

Tightening torque: 195 N·m (19.9 kgf-m, 143.8 ft-lb)

A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. 2) Remove the crank pulley cover.

ST1 ST2

ME-04262

5) Install the O-ring, and install the crank pulley cover. NOTE: Use new O-rings. ME-04261

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

3) Use the ST to lock the crank pulley, and remove the crank pulley bolt. ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET

ME-04261

6) Install the V-belts.

C: INSPECTION

ST1 ST2

ME-04262

4) Remove the crank pulley.

1) Check for oil leaks in the crank pulley cover. 2) Check the crank pulley for looseness.

B: INSTALLATION 1) Clean the crankshaft thread using compressed air. 2) Install the crank pulley. 3) Apply engine oil to the crank pulley bolt seat and thread. 4) Use the ST to lock the crank pulley, and tighten the crank pulley bolt. ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET

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Chain Cover MECHANICAL

14.Chain Cover

11) Disconnect the connector from the throttle body.

A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Drain the engine oil. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain engine coolant. 5) Remove the front exhaust pipe. 6) Lower the vehicle. 7) Change the bolt mounting position from (A) to (B), and completely open the front hood.

ME-04268

12) Remove the engine harness connector from the engine hanger bracket.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(A) ME-04407

(B)

(B)

13) Remove the engine hanger bracket.

ME-04396

8) Remove the air intake duct. 9) Remove the air intake boot assembly. 10) Disconnect the engine harness connector.

ME-04269

14) Remove the throttle body from the intake manifold. NOTE: Do not disconnect the inlet and outlet hoses of engine coolant. 15) Attach the ST. ST 18360AA020 HANGER

ME-04397

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Chain Cover MECHANICAL

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

24) Remove the front mounting bracket from the cradle.

ST

ME-04272

ME-04408

16) Remove the V-belts. 17) Remove the crank pulley. 18) Remove the grille bracket.

25) Remove the oil cooler pipe from the chain cover.

NOTE: Remove ten clips when removing the grille bracket.

ME-04263

ME-04479

19) Remove the reservoir tank. 20) Remove the radiator main fan & fan motor and radiator sub fan & fan motor. 21) Remove the radiator. 22) Support the engine with a lifting device and wire ropes. 23) Remove the front mount from the chain cover.

ME-04271

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Chain Cover MECHANICAL

26) Remove the chain cover. NOTE: Chain cover installation bolt has three different sizes. To prevent the confusion in installation, keep these bolts on container individually.

(B)

(B)

(B)

(A) (B)

(B) (A)

(A)

(B)

(B)

(B)

(A)

(A)

(B)

(B)

(B)

(B)

(B)

(B)

(B)

(B) (C)

(C) (C)

(C)

(B)

(A)

M6 × 21

(B)

(B)

(B)

(B)

(B)

(B)

(B)

(B)

(B)

(B)

M6 × 30

ME(H6DO)-52

(B)

(B)

(B)

(B)

ME-04264

(C)

M6 × 53

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Chain Cover MECHANICAL

B: INSTALLATION 1) Apply liquid gasket to the mating surfaces of the cylinder block, cylinder head and oil pan upper as shown in the figure.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

ME-03499

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Chain Cover MECHANICAL

2) Apply liquid gasket to the mating surface of the chain cover. NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 3.5±0.5 mm (0.138±0.020 in)

ME-03545

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Chain Cover MECHANICAL

3) Attach the chain cover and temporarily tighten the chain cover installation bolts. CAUTION: Do not install the chain cover installation bolts in wrong place.

(B)

(B)

(B)

(A) (B)

(B) (A)

(A)

(B)

(B)

(B)

(A)

(A)

(B)

(B)

(B)

(B)

(B)

(B)

(B)

(B) (C)

(C) (C)

(C)

(B)

(A)

(B)

(B)

(B)

M6 × 21

(B)

(B)

(B)

(B)

(B)

(B)

(B)

(B)

(B)

(B)

(B)

M6 × 30

ME-04264

(C)

M6 × 53

4) Tighten the chain cover installing bolts in the numerical order as shown in the figure.

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb) (34)

(28)

(29)

(9) (10) (20)

(24) (11)

(1)

(30)

(35)

(25)

(19)

(36) (8)

(7)

(6) (31)

(3)

(5)

(37)

(2) (4)

(21) (32)

(33)

(26) (27)

(23) (22)

(12)

(13)

(14)

(15) (16)

(17)

ME(H6DO)-55

(18)

(39)

(38)

ME-04266

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Chain Cover MECHANICAL

5) Install the oil cooler pipe to the chain cover.

12) Attach the grille bracket.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

ME-04479

ME-04263

6) Install front mounting bracket to the cradle.

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb)

13) Install the crank pulley. 14) Install the V-belts. 15) Install the throttle body to intake manifold. NOTE: Use a new gasket.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb) 16) Remove the ST (hanger) and install the engine hanger bracket. Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) ME-04272

7) Install the front mount.

Tightening torque: T1: 25 N·m (2.5 kgf-m, 18.4 ft-lb) T2: 45 N·m (4.6 kgf-m, 33.2 ft-lb) T1 ME-04269

17) Install the engine harness connector to the engine hanger bracket.

T2

ME-04273

8) Remove the lifting device and wire ropes. 9) Install the radiator. 10) Install the radiator main & fan motor and radiator sub fan & fan motor. 11) Install the reservoir tank.

ME(H6DO)-56

ME-04407

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Chain Cover MECHANICAL

18) Connect the connector to the throttle body.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (A)

(A)

(B)

(B)

ME-04268 ME-04396

19) Connect the engine harness connector.

C: INSPECTION 1) Check the chain cover surface for scratches or dents. 2) Check for oil leakage on the chain cover mating surface and installation part of crank pulley. If there is an oil leak from the oil seal, perform replacement with a new oil seal. ST 499585700 OIL SEAL GUIDE ME-04397

20) Install the V-belts. 21) Install the air intake boot assembly. 22) Install the air intake duct. 23) Install the front exhaust pipe. 24) Fill engine coolant. 25) Fill engine oil. 26) Make sure there is no oil leaks in the chain cover mating surface. 27) Install the under cover. 28) Install the collector cover. 29) Change the bolt mounting position from (B) to (A), and completely close the front hood.

Oil seal press-fit position: Chain cover end face — Position –1 mm (– 0.039 in) from the chain cover end face.

ST

(A)

(C) (A)

(B)

ME-04265

(A) Chain cover (B) Oil seal (C) Oil seal press-fit position (chain cover edge – 1 mm (–0.039 in) position)

ME(H6DO)-57

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Timing Chain Assembly MECHANICAL

15.Timing Chain Assembly A: LOCATION

(10)

(12)

(9)

(5)

(11)

(7)

(4)

(2)

(6)

(8)

(3) (1)

(13)

(14)

ME-03606

(1) (2) (3) (4) (5)

Chain tensioner (RH) Chain guide (Between cams, RH) Chain tensioner lever (RH) Chain guide (RH) Chain tensioner (LH)

(6) (7) (8) (9) (10)

Chain guide (Between cams, LH) Chain tensioner lever (LH) Chain guide (LH) Chain tensioner (Main) Chain tensioner lever (Main)

ME(H6DO)-58

(11) (12) (13) (14)

Chain guide (Main) Crank sprocket Idler sprocket Water pump sprocket

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Timing Chain Assembly MECHANICAL

B: REMOVAL NOTE: • When replacing the single part, perform the work with the engine installed to body. • To avoid mixing the timing chain component parts, separate each part after their removal. 1) Drain the engine oil. 2) Remove the radiator. 3) Remove the V-belts. 4) Remove the crank pulley. 5) Remove the chain cover. 6) Remove the chain tensioner (RH). NOTE: When removing chain tensioner (RH), hold the plunger by hand so that it does not come flying out.

ME-03461

7) Remove the chain guide (RH: between cams).

ME-03462

ME(H6DO)-59

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Timing Chain Assembly MECHANICAL

8) Remove the chain tensioner lever (RH).

ME-03463

9) Remove the chain guide (RH).

ME-03464

10) Remove the timing chain (RH).

ME(H6DO)-60

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Timing Chain Assembly MECHANICAL

11) Remove the chain tensioner (LH). NOTE: When removing chain tensioner (LH), hold the plunger by hand so that it does not come flying out.

ME-03465

12) Remove the chain guide (LH: between cams).

ME-03466

ME(H6DO)-61

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Timing Chain Assembly MECHANICAL

13) Remove the chain tensioner lever (LH).

ME-03467

14) Remove the chain guide (LH).

ME-03468

15) Remove the timing chain (LH).

ME(H6DO)-62

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Timing Chain Assembly MECHANICAL

16) Remove the chain tensioner (main). NOTE: When removing chain tensioner (main), hold the plunger by hand so that it does not come flying out.

ME-03469

17) Remove the chain guide (main).

ME-03470

ME(H6DO)-63

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Timing Chain Assembly MECHANICAL

18) Remove the chain tensioner lever (main).

ME-03471

19) Use the ST to lock the idler sprocket, and loosen the idler sprocket bolt. 20) Remove the idler sprocket bolts, and remove the idler sprocket and timing chain (main).

ME-03472

ST1 18355AA000 ST2 18334AA000

PULLEY WRENCH PULLEY WRENCH PIN SET

ME(H6DO)-64

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Timing Chain Assembly MECHANICAL

C: INSTALLATION NOTE: • Be careful that the foreign matter is not into or onto the assembled component during installation. • Apply engine oil to all component parts of the timing chain. 1) Prepare to attach the chain tensioner. (1) Insert the screw, spring pin and plunger into the tensioner body. (2) As shown in the figure, turn the rubber mat counterclockwise while holding the chain tensioner from above by hand. NOTE: Degrease the contact surface between the plunger head and rubber mat, so that they do not slip.

ME-03473

(3) Insert the stopper pin into the hole on the chain tensioner body. 2) Align the position of oil pump shaft knock pin to six o’clock position as shown in the figure.

ME-03474

3) Using ST, align the “Top mark” on crank sprocket to nine o’clock position as shown in the figure.

(A)

ME-03475

(A) Top mark

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Timing Chain Assembly MECHANICAL

4) Align the intake cam sprocket to twelve o’clock position as shown in the figure. RH

LH

(A)

(A) (A)

(A)

(B)

(C)

ME-03476

(A)

Align the marking (top mark) to twelve o’clock position.

(B)



(C)

47°

5) Align the exhaust cam sprocket to twelve o’clock position as shown in the figure. RH

LH

(A)

(A)

(B) (C) (A)

(A)

ME-03477

(A)

Align the marking (top mark) to twelve o’clock position.

(B)

5.5°

ME(H6DO)-66

(C)

3.5°

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Timing Chain Assembly MECHANICAL

6) Using ST, align the “Top mark” on crank sprocket to twelve o’clock position as shown in the figure. NOTE: • The #1 piston is positioned at TDC. • Do not rotate the crankshaft and cam sprocket before completing timing chain installation. • At this time, crank sprocket key is at three o’clock position. (A)

ME-03478

(A) Top mark

7) Install the chain guide (main).

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T

T

ME-03479

ME(H6DO)-67

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Timing Chain Assembly MECHANICAL

8) Install the idler sprocket and timing chain (main). (1) Match the timing chain mark (gold) to the timing mark position of the idler sprocket. (2) Align the idler sprocket timing mark at six o’clock position, and install the idler sprocket and timing chain. (3) Make sure that the timing chain mark (gold) is located at twelve o’clock position on the crank sprocket. (4) Use the ST to lock the idler sprocket, and install the idler sprocket bolt. ST1 18355AA000 PULLEY WRENCH ST2 18334AA000 PULLEY WRENCH PIN SET

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb) (A)

(B)

(A) ME-03480

(A)

Gold

(B)

Timing mark

9) Install the chain tensioner lever (main).

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T

ME-03481

ME(H6DO)-68

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Timing Chain Assembly MECHANICAL

10) Install the chain tensioner (main) and pull out the stopper pin. NOTE: The timing chain (main) line will be complete.

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T

T

ME-03482

11) Install the chain guide (LH).

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T

T ME-03483

ME(H6DO)-69

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Timing Chain Assembly MECHANICAL

12) Install the chain guide (LH: between cams).

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(2) Match the timing mark of exhaust cam sprocket (LH) to the timing chain mark (blue).

(B)

T

(A)

T

ME-03486 ME-03607

13) Install timing chain (LH). (1) Match the timing mark of intake cam sprocket (LH) to the timing chain mark (blue).

(B) (A)

ME-03485

(A) Blue (B) Timing mark

ME(H6DO)-70

(A) Blue (B) Timing mark

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Timing Chain Assembly MECHANICAL

(3) Install the timing chain to the water pump sprocket.

(A)

ME-03487

(A)

Water pump sprocket

(4) Match the timing mark of idler sprocket to the timing chain mark (gold).

(B)

(A)

ME-03488

(A)

Gold

(B)

Timing mark

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Timing Chain Assembly MECHANICAL

14) Install the chain tensioner lever (LH).

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T

ME-03489

15) Install the chain tensioner (LH) and pull out the stopper pin. NOTE: • Make sure that there is a bolt attached on the side face of the chain tensioner housing. • The timing chain (LH) line will be complete.

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T

T

ME-03490

ME(H6DO)-72

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Timing Chain Assembly MECHANICAL

16) Install the chain guide (RH).

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T

T

ME-03491

17) Install the chain guide (RH: between cams).

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

18) Install timing chain (RH). (1) Match the timing mark of intake cam sprocket (RH) to the timing chain mark (blue).

(A)

T (B)

ME-03493

ME-03492

(A) Blue (B) Timing mark

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Timing Chain Assembly MECHANICAL

(2) Match the timing mark of exhaust cam sprocket (RH) to the timing chain mark (blue).

(B)

(A)

ME-03494

(A) Blue (B) Timing mark

(3) Match the timing mark of idler sprocket to the timing chain mark (gold).

(B)

(A)

ME-03495

(A)

Gold

(B)

Timing mark

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Timing Chain Assembly MECHANICAL

19) Install the chain tensioner lever (RH).

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T

ME-03496

20) Install the chain tensioner (RH) and pull out the stopper pin. NOTE: The timing chain (RH) line will be complete.

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T

T ME-03497

21) After installation, perform the following confirmations. CAUTION: Always make sure to perform this confirmation. (1) Make sure that the timing mark of idler sprocket is aligned to three timing chain marks (gold). (2) Make sure that the twelve o’clock position on the crank sprocket is aligned to the timing chain (main) mark (gold). (3) Make sure that the LH side cam sprocket timing mark is aligned to the timing chain mark (blue). (4) Make sure that the RH side cam sprocket timing mark is aligned to the timing chain mark (blue).

ME(H6DO)-75

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Timing Chain Assembly MECHANICAL

(5) Make sure that all bolts are tightened at the specified torque. 22) Using the ST, turn the crankshaft in the direction of engine rotation, and make sure that there are no abnormal conditions. CAUTION: Always make sure to perform this confirmation. 23) Install the chain cover. 24) Install the crank pulley. 25) Install the V-belts. 26) Fill engine oil. 27) Make sure there is no oil leaks in the chain cover mating surface. 28) Install the radiator.

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Cam Sprocket MECHANICAL

16.Cam Sprocket

B: INSTALLATION

A: REMOVAL

1) Remove the cam sprocket. 2) Use the ST to lock the cam sprocket, and install the cam sprocket bolt.

NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the chain cover. 4) Remove the timing chain assembly. 5) Use the ST to lock the cam sprocket, and remove the cam sprocket bolt. ST 499977500 CAM SPROCKET WRENCH • IN side

Tightening torque: Tighten to 29.5 N·m (3.0 kgf-m, 21.8 ft-lb) of torque, and then tighten further by 45°. ST 499977500 CAM SPROCKET WRENCH • IN side

ST

ME-03403

• EX side ST

ST

ME-03403

• EX side ME-03404

ST

ME-03404

6) Remove the cam sprocket.

3) Install the timing chain assembly. 4) Install the chain cover. 5) Install the crank pulley. 6) Install the V-belts.

C: INSPECTION 1) Check the cam sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between cam sprocket and key.

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Crank Sprocket MECHANICAL

17.Crank Sprocket A: REMOVAL NOTE: When replacing the single part, perform the work with the engine installed to body. 1) Remove the V-belts. 2) Remove the crank pulley. 3) Remove the chain cover. 4) Remove the timing chain assembly. 5) Remove the crank sprocket (A).

(A)

ME-03608

B: INSTALLATION 1) Install the crank sprocket (A).

(A)

ME-03608

2) Install the timing chain assembly. 3) Install the chain cover. 4) Install the crank pulley. 5) Install the V-belts.

C: INSPECTION 1) Check the crank sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between crank sprocket and key.

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Camshaft MECHANICAL

18.Camshaft A: REMOVAL 1) Remove the engine from vehicle. 2) Remove the crank pulley. 3) Remove the chain cover. 4) Remove the timing chain assembly. 5) Remove the cam sprocket. 6) Remove the crank sprocket. 7) Remove the exhaust oil flow control solenoid valve. 8) Remove the camshaft position sensor. 9) Loosen the rocker cover bolts in the order indicated in the figure, and remove the rocker cover. • LH side (A)

(A)

(7)

(2)

(9)

(A)

(B) (5) (A)

(4)

FRONT

(3) (B)

(1) (A)

(A)

M6 × 37

(B)

(A) (8)

(6)

(B)

ME-03406

M6 × 23

• RH side (2)

(A)

(9)

(7)

(A)

(A) (B)

(5) (A)

FRONT

(4)

(3) (B) (B) (1)

(A)

(6)

(8)

(A) ME-03444

(A)

M6 × 37

(B)

M6 × 23

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Camshaft MECHANICAL

10) Loosen the camshaft cap bolts equally, a little at a time in numerical sequence, as shown in the figure. (6)

(10)

(8)

(2)

(11)

(4) (7)

(9)

FRONT

(15)

(13) (3)

(17)

(1)

(12)

(16)

(5)

(14)

11) Remove the camshaft caps and camshaft (RH). NOTE: Arrange camshaft caps in order so that they can be installed in their original positions. 12) Similarly, remove the camshaft (LH) and related parts.

ME(H6DO)-80

ME-04204

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Camshaft MECHANICAL

B: INSTALLATION

(2) Install O-rings to the front camshaft cap.

1) Apply engine oil to camshaft journals, and install the camshaft. 2) Install the camshaft cap. (1) Apply liquid gasket sparingly to back side of the front camshaft cap as shown in the figure.

NOTE: Use new O-rings. RH

LH

NOTE: • Install within 5 min. after applying liquid gasket. • Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to come out and flow toward cam journal, resulting in engine seizure.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 2.0±0.5 mm (0.079±0.020 in) RH

LH

ME-05734

(3) Apply a thin coat of engine oil to the cap journal surface, and install the camshaft cap to the camshaft.

ME-05733

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Camshaft MECHANICAL

(4) Gradually tighten the camshaft cap in at least two stages in the numerical order shown in the figure, then tighten to specified torque.

Tightening torque: (1) — (12): 16 N·m (1.6 kgf-m, 11.8 ft-lb) (13) — (17): 9.75 N·m (1.0 kgf-m, 7.2 ft-lb) (8)

(12)

(10)

(16)

(7)

(14)

(11)

(9)

FRONT

(3)

(5) (15)

(1)

(17)

(6)

(2)

(13)

(4)

ME-04205

(5) After tightening the camshaft cap, ensure the camshaft rotates only slightly while holding it at base circle. 3) Install the rocker cover. (1) Install the rocker cover gasket to the rocker cover. NOTE: Use a new rocker cover gasket. (2) Apply liquid gasket sparingly to the mating surface of cylinder head and rocker cover as shown in the figure. NOTE: • Install within 5 min. after applying liquid gasket. • Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to come out and flow toward cam journal, resulting in engine seizure.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 3.5±0.5 mm (0.138±0.020 in)

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Camshaft MECHANICAL

• LH side (A)

(B) ME-03410

(A)

90 mm (3.543 in) or more

(B)

105 mm (4.134 in) or more

• RH side (A)

(B) ME-03411

(A)

80 mm (3.150 in) or more

(B)

100 mm (3.937 in) or more

ME(H6DO)-83

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Camshaft MECHANICAL

(3) Tighten the rocker cover bolts in the numerical order as shown in the figure.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) • LH side (A)

(3)

(1)

(A)

(8)

(A)

(B) (5) (A)

(6)

FRONT

(7) (B)

(9) (A)

(A)

(A)

M6 × 37

(B)

(2)

(4)

(B)

ME-03412

M6 × 23

• RH side (A)

(8)

(1)

(3)

(A)

(A) (B) (5)

(A)

FRONT

(6)

(7) (B) (B) (9)

(A)

(4)

(2)

(A) ME-03413

(A)

M6 × 37

(B)

M6 × 23

4) Install the crank sprocket. 5) Install the cam sprocket. 6) Install the timing chain assembly. 7) Install the chain cover. 8) Install the crank pulley. 9) Install the engine to the vehicle.

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Camshaft MECHANICAL

C: INSPECTION 1) Measure and inspect the degree of bending. Repair or replace if necessary.

Camshaft bend limit: 0.020 mm (0.00079 in)

6) Measure the outside diameter of camshaft journal. If the journal diameter is not within specification, check the oil clearance.

Standard mm (in)

ME-00539

2) Check the journal for damage and wear. Replace if faulty. 3) Check the cutout portion used for camshaft sensor for damage. Replace if faulty. 4) Check the cam face condition; remove the minor faults by grinding with oil stone. Replace if there is uneven wear or others. 5) Measure the cam lobe height “H” and cam base circle diameter “A”. If it exceeds the standard or offset wear occurs, replace it.

Cam lobe height H: Standard Intake 45.90 — 46.00 mm (1.8071 — 1.8110 in) Exhaust 44.65 — 44.75 mm (1.7579 — 1.7618 in)

Camshaft journal Front Except for front 37.946 — 37.963 25.946 — 25.963 (1.4939 — 1.4946) (1.0215 — 1.0222)

7) Measure the oil clearance of camshaft journal. (1) Clean the camshaft cap and cylinder head camshaft journal. (2) Place the camshaft on cylinder head. (Without installing the valve lifter) (3) Place a plastigauge across each camshaft journals. (4) Gradually tighten the camshaft cap in at least two stages in the numerical order shown in the figure, then tighten to specified torque. Do not turn the camshaft. (5) Remove the camshaft cap. (6) Measure the widest point of the plastigauge on each journal. If oil clearance exceeds the standard, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set.

Camshaft oil clearance: Standard 0.037 — 0.072 mm (0.0015 — 0.0028 in)

Cam base circle diameter A: Standard Intake 36.00 mm (1.4173 in) Exhaust 36.00 mm (1.4137 in)

ME-00119

(7) Completely remove the plastigauge. 8) Measure the thrust clearance of camshaft with the dial gauge set at end of camshaft. If the clearance is not within the standard or there is offset wear, replace the camshaft caps and cylinder head as a set. If necessary replace the camshaft.

H

Camshaft thrust clearance:

A

ME-03414

Standard Intake 0.075 — 0.135 mm (0.0030 — 0.0053 in) Exhaust 0.075 — 0.135 mm (0.0030 — 0.0053 in)

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Cylinder Head MECHANICAL

19.Cylinder Head A: REMOVAL 1) Remove the engine from vehicle. 2) Remove the crank pulley. 3) Remove the chain cover. 4) Remove the timing chain assembly. 5) Remove the cam sprocket. 6) Remove the crank sprocket. 7) Remove the camshaft. 8) Remove the seal bolt shown in the figure.

FRONT

ME-03524

9) Remove the cylinder head bolts in the numerical order as shown in the figure. NOTE: Leave bolts (2) and (4) engaged by three or four threads to prevent the cylinder head from falling. (8)

(6)

(2) (4) FRONT

(1) (3)

(5)

(7)

10) While tapping the cylinder head with a plastic hammer, separate it from cylinder block. 11) Remove the bolts (2) and (4) to remove cylinder head. 12) Remove the cylinder head gasket.

ME(H6DO)-86

ME-03415

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Cylinder Head MECHANICAL

CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. 13) Similarly, remove the cylinder head (RH).

B: INSTALLATION 1) Apply liquid gasket to the mating surface of cylinder block shown in the figure. NOTE: • Install within 5 min. after applying liquid gasket. • Do not apply liquid gasket excessively. If too much is applied, remove any liquid gasket that is squeezed out.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 3.5±1.0 mm (0.138±0.039 in) • LH side

(A)

(C)

(B)

(D)

(E)

(F)

ME-04497

(A)

59 mm (2.323 in)

(C)

20 mm (0.787 in)

(E)

4 mm (0.157 in)

(B)

2 mm (0.079 in)

(D)

7 mm (0.276 in)

(F)

4 mm (0.157 in)

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Cylinder Head MECHANICAL

• RH side

(A)

(C) (B)

(D)

(E)

ME-03445

(A) (B)

17 mm (0.669 in) 2 mm (0.079 in)

(C) (D)

9 mm (0.354 in) 4 mm (0.157 in)

(E)

4 mm (0.157 in)

2) Install the cylinder head gaskets LH and RH onto the cylinder block. NOTE: Use a new cylinder head gasket. 3) Apply liquid gasket to the mating surface of cylinder head gasket shown in the figure. NOTE: • Install within 5 min. after applying liquid gasket. • Do not apply liquid gasket excessively. If too much is applied, remove any liquid gasket that is squeezed out.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 3.5±1.0 mm (0.138±0.039 in)

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Cylinder Head MECHANICAL

• LH side

ME-04498

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Cylinder Head MECHANICAL

• RH side

ME-03544

4) Attach the cylinder head to the cylinder block. CAUTION: Be careful not to scratch the mating surface of cylinder head and cylinder block. 5) Tighten the cylinder head bolts. (1) Apply a thin coat of engine oil to washers and cylinder head bolt threads. (2) Mount the cylinder head onto the cylinder block, then tighten the bolts with a torque of 20 N·m (2.0 kgfm, 14.8 ft-lb) in the order indicated in the figure. (3) Tighten the bolts with a torque of 50 N·m (5.1 kgf-m, 36.9 ft-lb) in the order indicated in the figure. (4) Loosen all bolts by 180° in the reverse order of installing, and loosen them further by 180°. (5) Tighten the bolts with torque of 20 N·m (2.0 kgf-m, 14.8 ft-lb) in numerical sequence as shown in the figure. (6) Tighten the bolts (1) — (4) in the order indicated with a torque of 48 N·m (4.9 kgf-m, 35.4 ft-lb). (7) Tighten the bolts (5) — (8) in the order indicated with a torque of 44 N·m (4.5 kgf-m, 32.5 ft-lb). (8) Tighten all bolts 90° in the numerical order as shown in the figure.

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(9) Tighten the bolt (1) — (4) by 45° in the numerical order. (1)

(3)

(7)

(5)

FRONT

(8) (6)

(4)

(2)

ME-03417

6) Install the seal bolt shown in the figure. NOTE: Before installing seal bolts, apply a sealing material to bolt threads.

SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FRONT

ME-03524

7) Install the camshaft. 8) Install the crank sprocket. 9) Install the cam sprocket. 10) Install the timing chain assembly. 11) Install the chain cover. 12) Install the crank pulley. 13) Install the engine to the vehicle.

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C: DISASSEMBLY 1) Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE 2) Remove the valve lifter. 3) Compress the valve spring using ST, and remove the valve spring retainer key, each valve and valve spring. ST 499718000 VALVE SPRING REMOVER NOTE: • Mark each valve to prevent confusion. • Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals. • Keep all the removed parts in order for re-installing in their original positions. • For removal and installation procedures of the valve guide, intake valve oil seal and exhaust valve oil seal, refer to “INSPECTION”.

• Install the valve spring with the painted side facing to retainer. (1)

(2)

(4)

(3) ME-03418

(1) (2) (3) (4)

Seat Valve spring Retainer Painted face

(4) Set the ST on valve spring. ST 499718000 VALVE SPRING REMOVER

ST ST

ME-03446 ME-03446

D: ASSEMBLY 1) Install the valve spring and valve. (1) Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE (2) Coat the stem of each valve with engine oil and insert the valve into valve guide. NOTE: When inserting the valve into valve guide, use special care not to damage the oil seal lip. (3) Install the valve spring and retainer. NOTE: • Be sure to install the valve spring with its closecoiled end facing the seat on cylinder head.

(5) Compress the valve spring and fit the valve spring retainer key. (6) After installing, tap the valve spring retainers lightly with a wooden hammer for better seating. 2) Apply oil to the surface of valve lifter. 3) Install the valve lifter.

E: INSPECTION 1. CYLINDER HEAD 1) Make sure that there are no cracks or other damages. Perform visual check, and use liquid penetrant tester on the important sections. Check that there are no marks of gas leaking or water leaking on gasket installing surface. 2) Set the cylinder head on ST. ST 18250AA010 CYLINDER HEAD TABLE 3) Check for warpage at mating surface between the cylinder block and cylinder head using a straight edge (A) and thickness gauge (B). If the warpage exceeds limit, replace the cylinder head.

Warping limit: 0.020 mm (0.0008 in) Standard height of cylinder head: 124±0.05 mm (4.88±0.0020 in)

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NOTE: Uneven torque for the cylinder head bolts can cause warpage. When reinstalling, pay special attention to the torque so as to tighten evenly.

2) If the clearance between valve guide and valve stem exceeds the standard, replace the valve guide or valve itself, whichever shows the greater amount of wear or damage. See the following procedure for valve guide replacement.

Valve guide inner diameter: 5.500 — 5.512 mm (0.2165 — 0.2170 in) (A)

(B) ME-00551

2. VALVE SEAT Inspect the intake and exhaust valve seats, and correct the contact surfaces with a valve seat cutter if they are defective or when valve guides are replaced.

Valve stem outer diameters: Intake 5.455 — 5.470 mm (0.2148 — 0.2154 in) Exhaust 5.445 — 5.460 mm (0.2144 — 0.2150 in) (1) Place the cylinder head on ST1 with the combustion chamber upward so that valve guides fit the holes in ST1. (2) Insert the ST2 into valve guide and press it down to remove the valve guide. ST1 18250AA010 CYLINDER HEAD TABLE ST2 499765700 VALVE GUIDE REMOVER

Contacting width of valve seat W: Standard Intake 1.0 mm (0.039 in) Exhaust 1.5 mm (0.059 in)

ME-00553

(3) Turn the cylinder head upside down and place the ST as shown in the figure. ST 18251AA050 VALVE GUIDE ADJUSTER (INTAKE SIDE) ST 18251AA060 VALVE GUIDE ADJUSTER (EXHAUST SIDE)

W

ME-00127

3. VALVE GUIDE 1) Check the clearance between valve guide and valve stem. The clearance can be checked by measuring respectively the outer diameter of valve stem with a micrometer and the inner diameter of valve guide with a caliper gauge.

ST

L

Clearance between the valve guide and valve stem: Standard Intake 0.030 — 0.057 mm (0.0012 — 0.0022 in) Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)

ME-00757

(4) Before installing a new valve guide, make sure that neither scratches nor damages exist on the inner surface of valve guide holes in cylinder head.

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(5) Coat a new valve guide with sufficient oil, put it into the cylinder, and insert the ST1 into the valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499765700 VALVE GUIDE REMOVER ST2 18251AA050 VALVE GUIDE ADJUSTER (INTAKE SIDE) ST2 18251AA060 VALVE GUIDE ADJUSTER (EXHAUST SIDE)

4. INTAKE AND EXHAUST VALVE 1) Inspect the flange and stem of valve, and replace if damaged, worn or deformed, “H” exceeds the standard, or if there is uneven wear.

Head edge thickness H: Standard Intake (A) 1.0 mm (0.039 in) Exhaust (B) 1.2 mm (0.047 in)

ST1 ST2

(A)

H

ME-00130

90

+1 0

90

+1 0

(6) Check the valve guide protrusion amount “L”.

Valve guide protrusion amount L: Intake 8.6 — 9.0 mm (0.3386 — 0.3543 in) Exhaust 10.7 — 11.1 mm (0.4213 — 0.4370 in) (7) Ream the inside of valve guide using ST. Put the reamer in valve guide, and slowly rotate the reamer clockwise while pushing it lightly. Bring the reamer back while rotating it clockwise. ST 499765900 VALVE GUIDE REAMER NOTE: • Apply engine oil to the reamer when reaming. • If the inner surface of valve guide is damaged, the edge of reamer should be slightly ground with oil stone. • If the inner surface of valve guide becomes lustrous and the reamer does not chip, use a new reamer or remedy the reamer. (8) After reaming, clean the valve guide to remove chips. (9) Recheck the contact condition between valve and valve seat after replacing the valve guide.

(B)

H

ME-02096

2) Put a small amount of grinding compound on the seat surface, and lap the valve and seat surface. Install a new valve oil seal after lapping. NOTE: It is possible to differentiate between the intake valve and the exhaust valve by their overall length.

Valve overall length: Intake 103.5 mm (4.075 in) Exhaust 103.2 mm (4.063 in)

5. VALVE SPRING 1) Check the valve springs for damage, free length, and tension. Replace the valve spring if it is not within the standard value presented in the table.

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2) To measure the squareness of the valve spring, stand the valve spring on a surface plate and measure its deflection at the top of the spring using a try square. Free length

mm (in) 49.06 (1.9315)

Set Tension/spring height N (kgf, lb)/mm (in) Lift Squareness

182 — 210 (18.6 — 21.4, 40.9 — 47.2) /31.0 (1.220 in)

7. VALVE LIFTER 1) Perform visual check on the valve lifter. 2) Measure the valve lifter outer diameter.

Outer diameter of valve lifter: 32.959 — 32.975 mm (1.2976 — 1.2982 in)

316 — 350 (32.2 — 35.7, 71.0 — 78.7) /21.0 (0.827 in) 2.5°, 2.1 mm (0.083 in) or less

ME-00134

3) Measure the inner diameter of valve lifter hole of cylinder head.

Inner diameter of valve lifter mating surface: 32.994 — 33.016 mm (1.2990 — 1.2998 in) ME-00132

6. INTAKE AND EXHAUST VALVE OIL SEAL 1) For the following, replace the oil seal with a new part. • When the lip is damaged. • When the spring is out of the specified position. • When readjusting the surfaces of valve and valve seat. • When replacing the valve guide. 2) Set the cylinder head on ST1. 3) Using the ST2, press in the oil seal. ST1 18250AA010 CYLINDER HEAD TABLE ST2 499585500 VALVE OIL SEAL GUIDE NOTE: • Apply engine oil to oil seal before press-fitting. • When press-fitting the oil seal, do not use a hammer or strike in.

ME-03447

4) Check the clearance between valve lifter and valve lifter mating surface. The clearance can be determined from the measured value of the valve lifter outer diameter and valve lifter mating surface inner diameter. If it is not within the standard or there is uneven wear in the inner surface, replace the cylinder head.

Clearance between valve lifter and valve lifter mating surface: Standard 0.019 — 0.057 mm (0.0007 — 0.0022 in)

ME-00548

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20.Cylinder Block

11) Remove the crankshaft position sensor plate.

A: REMOVAL NOTE: Before conducting this procedure, drain the engine oil completely. 1) Remove the engine from vehicle. 2) Remove the crank pulley. 3) Remove the chain cover. 4) Remove the timing chain assembly. 5) Remove the cam sprocket. 6) Remove the crank sprocket. 7) Remove the camshaft. 8) Remove the cylinder head. 9) Use the ST to lock the crankshaft, and remove the drive plate. ST 498497100 CRANKSHAFT STOPPER

ME-00558

12) Rotate the engine to set oil pan upper. 13) Remove the bolts which secure oil pan lower to oil pan upper.

ME-03419

14) Insert an oil pan cutter blade into the gap between oil pan upper and oil pan lower, and remove the oil pan lower. CAUTION: Do not use a screwdriver or similar tools in place of oil pan cutter. 15) Remove the oil cooler connector and remove the oil cooler.

ST ME-02664

(B)

10) Remove the crankshaft position sensor.

(C)

(D)

(A)

(A) (B) (C) (D)

ME-03498

LU-02384

Oil cooler connector Oil cooler O-ring Oil pan upper

16) Remove the oil pump. 17) Remove the oil level switch.

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18) Remove the thermostat cover, and then remove the thermostat. (A)

(B) (C)

ME-04496

(A) Oil pan upper (B) Thermostat (C) Thermostat cover

19) Remove the oil pump cover.

(4) (2)

(8)

(6)

(10)

(12)

(7)

(5)

(3) (1)

(9)

(11) ME-03420

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20) Face the front of the engine up, standing the engine on one end.

• After removing the two connecting rod connection bolts, turning the crankshaft (ST) counterclockwise will remove the connecting rod cap. • Mark each connecting rod cap and piston with connecting rod cap number and piston number. • The removal of all connecting rod caps and pistons are performed in three separate steps. First, remove the #1 and #4 connecting rod caps and pistons are simultaneously, then the #2 and #5 connecting rod caps and pistons simultaneously, and then the #3 and #6 connecting rod caps and pistons simultaneously. (1) Using the ST, turn the crankshaft and set the #1 piston at the mid point between TDC and BDC. ST 18252AA000 CRANKSHAFT SOCKET (2) Remove the two #1 connecting rod cap connection bolts, and remove the connecting rod cap.

ME-03421

21) Remove ten O-rings from the underside of the cylinder block.

(A)

(A)

ME-03423

(A) #1 connecting rod cap

ME-03422

22) Mark the direction of front and the number of connecting rod caps. 23) Remove the #1 and #4 connecting rod caps and pistons from the cylinder block. NOTE: • Use 3/8 inch (9.5sq.) for the extension and TORX® socket (E12).

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(3) Remove the two #4 connecting rod cap connection bolts, and remove the connecting rod cap.

(5) Push the #1 connecting rod in the direction of the arrow, and remove the #1 piston and connecting rod from the cylinder block.

(A) (A)

(B)

ME-03426

(A) #1 connecting rod (B) Crank pin

(6) Using the ST, turn the crankshaft and separate the positions of the crank pin and the large end of the #4 connecting rod. ST 18252AA000 CRANKSHAFT SOCKET

ME-03424 (B)

(A) #4 connecting rod cap

(A)

(4) Using the ST, turn the crankshaft and separate the positions of the crank pin and the large end of the #1 connecting rod. ST 18252AA000 CRANKSHAFT SOCKET

(A) (A)

(B) (B)

ME-03427

(A) #4 connecting rod (B) Crank pin

(A)

(B)

ME-03425

(A) #1 connecting rod (B) Crank pin

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(7) Push the #4 connecting rod in the direction of the arrow, and remove the #4 piston and connecting rod from the cylinder block.

26) Face the cylinder block (RH) up.

(A)

(A) (B)

ME-03428

(B)

(A) #4 connecting rod (B) Crank pin

24) Remove the #2 and #5 connecting rods and pistons from the cylinder block in the same manner. ST 18252AA000 CRANKSHAFT SOCKET 25) Remove the #3 and #6 connecting rods and pistons from the cylinder block in the same manner. ST 18252AA000 CRANKSHAFT SOCKET

ME-03429

(A) Cylinder block (RH) (B) Cylinder block (LH)

27) Remove the upper bolt.

FRONT

ME-03433

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28) Loosen the cylinder block bolts in the order indicated in the figure, and separate cylinder block (RH) and (LH). NOTE: Confirm that the crankshaft is remaining in the cylinder block (LH). If the cylinder block (RH) is lifted carelessly when separating, the crankshaft may stick to cylinder block (RH), then fall off. (1) (7)

(9)

(14)

(12)

(6)

(4)

FRONT

(3)

(5)

(11)

(13)

(10)

(8)

(2) ME-03430

29) Remove the rear oil seal. 30) Remove the crankshaft from cylinder block (LH). 31) Remove the crankshaft bearings from cylinder block using a hammer handle. NOTE: • Do not confuse the combination of crankshaft bearings. • Press the bearing at the end opposite to locking lip.

B: INSTALLATION 1) After setting the cylinder block to ST, install the crankshaft bearing. ST 18232AA000 ENGINE STAND NOTE: Apply a coat of engine oil to the bearing and crankshaft journal. 2) Mount the crankshaft in cylinder block (LH).

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3) Apply liquid gasket to the mating surfaces of cylinder block (RH). CAUTION: Do not allow liquid gasket to run over into oil passages, bearing grooves, etc. NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 1.0±0.2 mm (0.039±0.008 in)

FRONT

ME-03431

4) Attach cylinder block (RH) to cylinder block (LH). 5) Apply a coat of engine oil to the washer and bolt thread. 6) Tighten all bolts in the numerical order as shown in the figure.

Tightening torque: 12 N·m (1.2 kgf-m, 8.9 ft-lb) (14) (8)

(6)

(1)

(3)

(9)

(11)

FRONT

(12)

(10)

(4)

(2)

(5)

(7)

(13) ME-03432

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7) Retighten all bolts in the numerical order as shown in the figure.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb) (14) (8)

(6)

(1)

(3)

(9)

(11)

FRONT

(12)

(10)

(4)

(2)

(5)

(7)

(13) ME-03432

8) Tighten all bolts by 90° in numerical order as shown in the figure. (14) (8)

(6)

(1)

(3)

(9)

(11)

FRONT

(12)

(10)

(4)

(2)

(5)

(7)

(13) ME-03432

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9) Install the upper bolt to cylinder block.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) NOTE: Remove any liquid gasket squeezed out onto the seal surface between the chain cover and oil pan upper, after tightening the cylinder block connecting bolts.

FRONT

ME-03433

10) Apply a coat of engine oil to the oil seal periphery and install the rear oil seal using ST1 and ST2.

11) Face the front of the engine up, standing the engine on one end.

NOTE: Use a new rear oil seal. ST1 499597100 CRANKSHAFT OIL SEAL GUIDE ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER

(A)

(B)

ST2

ST1

ME-00570

(A) Rear oil seal (B) Drive plate installation bolt ME-03421

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12) Attach the piston ring and oil ring to the piston. (1) Position the top ring gap at (A) in the figure. (2) Position the second ring gap at (B). 180˚

(A)

(B)

ME-02066

(3) Using ST, press-fit the piston into cylinder block. NOTE: When inserting the piston into the cylinder block, perform according to the items listed below. • Insert while lightly tapping the top of the piston with the handle of a plastic hammer. • Insert while making sure that the large end of the connecting rod does not scratch the cylinder liner. • Insert while continually making sure that the large end of the connecting rod does not touch the crankshaft. ST 398744300 PISTON GUIDE

(3) Position the upper rail gap at (C) in the figure. (4) Position the expander gap at (D) in the figure. (5) Position the lower rail gap at (E) in the figure. (A)

(B)

(E)

(C) 25˚

35˚

(D)

ME-02067

CAUTION: • Make sure ring gaps do not face the same direction. • Make sure ring gaps are not within the piston skirt area. • Assemble so that the stamp mark N faces towards the top of the piston. 13) Install the #1 piston and connecting rod to the cylinder block. (1) Apply engine oil to the outer circumference of the piston and in the cylinder block. (2) Face the front mark of piston (A) towards the front of the engine, and set the piston to the ST.

(A)

(B)

ME-03435

(A) #1 connecting rod (B) Crank pin

(4) Using the ST, turn the crankshaft and match the positions of the crank pin and the large end of the connecting rod. ST 18252AA000 CRANKSHAFT SOCKET

(A)

ME-03609

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(5) Install the connecting rod cap.

NOTE: Use new O-rings.

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb)

(A)

T ME-03422

T

ME-03437

(A) #1 connecting rod

14) In the same procedures as for the #1 piston, install the piston and connecting rods to the cylinder block, in the order of #2, #3, #4, #5 and #6. 15) Install the O-ring to the underside of the cylinder block.

16) Apply liquid gasket to the mating surface of oil pan upper. NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 5.0±1.0 mm (0.20±0.04 in)

ME-03438

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17) Temporarily tighten the oil pan upper. 18) Tighten the oil pan upper installing bolts in the numerical order as shown in the figure.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

(9) (11)

(5)

(7)

(1)

(3)

(6)

(8)

(10) (12)

(4)

(2) ME-03440

19) Install the thermostat and thermostat cover.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

21) Install the oil pump. 22) Tighten the oil cooler connector to install the oil cooler to the oil pan upper.

Tightening torque: 54 N·m (5.5 kgf-m, 39.8 ft-lb)

(A)

NOTE: Use new O-rings.

(B)

(C)

(D)

T (B) (C) (A)

(A) (B) (C) (D) ME-04496

(A) Oil pan upper (B) Thermostat (C) Thermostat cover

20) Install the oil level switch.

ME(H6DO)-107

Oil cooler connector Oil cooler O-ring Oil pan upper

LU-02385

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23) Apply liquid gasket to the matching surface of oil pan lower. NOTE: Install within 5 min. after applying liquid gasket.

26) Install the crankshaft position sensor.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 5.0±1.0 mm (0.20±0.04 in)

ME-03498

27) Using the ST, install the drive plate. ST 498497100 CRANKSHAFT STOPPER

Tightening torque: 90 N·m (9.2 kgf-m, 66.4 ft-lb) LU-02377

24) Tighten the oil pan lower installing bolts in the numerical order as shown in the figure.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) (7)

(8) ST

(6) (9) (5)

ME-02664

(10)

(4) (11) (3)

(12) (2)

(1)

(13) ME-03441

25) Install the crankshaft position sensor plate.

ME-00558

28) Install the cylinder head. 29) Install the camshaft. 30) Install the crank sprocket. 31) Install the cam sprocket. 32) Install the timing chain assembly. 33) Install the chain cover. 34) Install the crank pulley. 35) Install the engine to the vehicle.

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C: DISASSEMBLY

(9)

7) Separate the piston and connecting rod. NOTE: Mark the direction of front side to each connecting rod. 8) Remove the snap ring on other end from the piston using a snap ring pliers. (Snap ring type) 9) Remove the circlip on other end from the piston using a flat tip screwdriver. (Circlip type)

(6) (8)

(5)

(7)

NOTE: Be careful not to damage the piston, by wrapping the tip of flat tip screwdriver with tape. 10) Remove the plug and orifice from the cylinder block as necessary.

(4)

(6) (5)

(3)

D: ASSEMBLY

(1) (2)

(9) ME-06092

(6) (8)

(5)

(7)

(1) Connecting rod (2) Connecting rod bearing (3) Piston (4) (5) (6) (7) (8) (9)

(4)

Piston pin Snap ring Circlip Oil ring Second ring Top ring

(6) (5)

(1)

(2)

NOTE: To prevent confusion of various parts, mark each part. 1) Remove the connecting rod bearing. 2) Remove the piston rings using piston ring expander. 3) Remove the oil ring by hand.

ME-06093

(1) (2) (3) (4) (5) (6) (7) (8) (9)

NOTE: Arrange the removed piston rings in proper order, to prevent confusion. 4) Remove the snap ring on one end from the piston using a snap ring pliers. (Snap ring type) 5) Remove the circlip on one end from the piston using a flat tip screwdriver. (Circlip type) NOTE: Be careful not to damage the piston, by wrapping the tip of flat tip screwdriver with tape. 6) Remove the piston pin from the piston.

(3)

Connecting rod Connecting rod bearing Piston Piston pin Snap ring Circlip Oil ring Second ring Top ring

1) Apply engine oil to the surface of the connecting rod bearing. Attach the connecting rod bearing to the connecting rod.

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Cylinder Block MECHANICAL

2) Install the circlip on one end of the piston using a flat tip screwdriver. (Circlip type) NOTE: • Be careful not to damage the piston, by wrapping the tip of flat tip screwdriver with tape. • Make sure the circlip is firmly inserted into the circlip groove. • After installing the circlip, rotate the circlip so that its end part (a) and the cutout portion of circlip groove (b) do not match.

4) Set the piston to the connecting rod. NOTE: Align the front mark of piston and the connecting rod direction correctly as shown in the figure. (b)

(a)

(c) (c)

(a)

(b)

ME-06033 (a)

(a) RH side (#1, #3 and #5) (b) LH side (#2, #4 and #6) (c) Front mark

(b) ME-06032

3) Install the snap ring on one end of the piston using a snap ring pliers. (Snap ring type)

5) Apply engine oil to the piston pin, and attach the piston pin.

NOTE: Make sure the snap ring is firmly inserted into the snap ring groove.

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6) Install the circlip on the piston using a flat tip screwdriver. (Circlip type)

E: INSPECTION

NOTE: • Be careful not to damage the piston and piston pin, by wrapping the tip of flat tip screwdriver with tape. • Make sure the circlip is firmly inserted into the circlip groove. • After installing the circlip, rotate the circlip so that its end part (a) and the cutout portion of circlip groove (b) do not match.

1) Visually check for cracks or damage. Use liquid penetrant tester on the important sections. 2) Check the oil passages for clogging. 3) Inspect the cylinder block surface that mates with cylinder head for warping by using a straight edge If the warpage exceeds limit, replace the cylinder block.

1. CYLINDER BLOCK

Warping limit: 0.020 mm (0.0008 in) Standard height of cylinder block: 202 mm (7.95 in)

2. CYLINDER AND PISTON 1) The cylinder bore size is stamped on the front upper face of the cylinder block.

(a)

NOTE: • Measurement should be performed at a temperature of 20°C (68°F). • Standard sized pistons are classified into two grades, “A” and “B”. These grades should be used as guide lines in selecting a standard piston.

(b)

Standard diameter: A: 92.005 — 92.015 mm (3.6222 — 3.6226 in) B: 91.995 — 92.005 mm (3.6218 — 3.6222 in)

(a)

(b) ME-06034

7) Install the snap ring on the piston using a snap ring pliers. (Snap ring type) NOTE: Make sure the snap ring is firmly inserted into the snap ring groove. 8) Install the oil ring upper rail, expander and lower rail by hand. 9) Install the second ring and top ring using piston ring expander. 10) Install the plug and orifice to the cylinder block as necessary.

B B B

#6 #4 #5 #2 #3 #1

2 4

(B) 2 4

#7 #6 #5 #4 #3 #2 #1

B A B

(A)

(C) ME-00585

(A) Main journal size mark (B) Cylinder bore size mark (C) Cylinder block (RH) – (LH) combination mark

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2) Measure inner diameter of each cylinder. Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights as shown in the figure, using a cylinder bore gauge. NOTE: Measurement should be performed at a temperature of 20°C (68°F).

Taper: Standard 0.030 mm (0.0012 in)

Piston outer diameter: Standard A: 92.005 — 92.015 mm (3.6222 — 3.6226 in) B: 91.995 — 92.005 mm (3.6218 — 3.6222 in) 0.25 mm (0.0098 in) oversize 92.245 — 92.265 mm (3.6317 — 3.6325 in) 0.50 mm (0.0197 in) oversize 92.495 — 92.515 mm (3.6415 — 3.6423 in)

Out-of-roundness: Standard 0.010 mm (0.0004 in) (A) (B)

H ME-00172

5) Calculate the clearance between cylinder and piston. NOTE: Measurement should be performed at a temperature of 20°C (68°F). H1

H2 H3

Unit: mm (in)

(A) (B) H1: H2: H3:

ME-00586

Cylinder to piston clearance at 20°C (68°F): Standard –0.010 — 0.010 mm (–0.0004 — 0.0004 in) 6) Boring and honing: (1) If any of the measured value of taper, out-ofroundness or cylinder-to-piston clearance is out of standard or if there is any damage on the cylinder wall, rebore it to replace with an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and replaced with oversize pistons.

Thrust direction Piston pin direction 10 mm (0.39 in) 45 mm (1.77 in) 80 mm (3.15 in)

3) When the piston is to be replaced due to general or cylinder wear, select a suitable sized piston by measuring the piston clearance. 4) Measure outer diameter of each piston. Measure the outer diameter of each piston at the height as shown in the figure. (Thrust direction)

NOTE: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, when measuring the cylinder diameter, wait until it has cooled to room temperature.

Cylinder inner diameter boring limit (diameter): To 92.515 mm (3.6717 in)

NOTE: Measurement should be performed at a temperature of 20°C (68°F).

Piston grade point H: 37.3 mm (1.4685 in)

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Cylinder Block MECHANICAL

3. PISTON AND PISTON PIN

4. PISTON RING

1) Check the piston and piston pin for damage, cracks or wear. And check the piston ring groove for wear or damage. Replace if faulty. 2) Measure the clearance between piston and cylinder in each cylinder. If the clearance exceeds the standard, replace the piston, or rebore the cylinder so that an oversize piston can be used. 3) Make sure the piston pin can be inserted into the piston pin hole by a thumb at 20°C (68°F). Replace if faulty.

1) If the piston ring is broken, damaged or worn, or if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of the same size as piston. NOTE: • The top ring and second ring have the mark to determine the direction for installing. When attaching the ring to the piston, face these marks towards the top side. • Oil ring consists of the upper rail, expander and lower rail. When installing to the piston, be careful of the direction of each rail.

Clearance between piston pin hole and piston pin: Standard 0.004 — 0.008 mm (0.0002 — 0.0003 in)

(A)

(B) (a) (b) (C)

(c) ME-00591

ME-00173

(A) (B) (C) (a) (b) (c)

Top ring Second ring Oil ring Upper rail Expander Lower rail

2) Squarely place the piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge. Standard mm (in) ME-00174

4) Check the snap ring installation groove (A) on the piston for burr. If necessary, remove burr from the groove so that the piston pin can lightly move.

Piston ring gap

Top ring

0.20 — 0.25 (0.0079 — 0.0098)

Second ring

0.40 — 0.50 (0.0157 — 0.0197)

Oil ring

0.20 — 0.50 (0.0079 — 0.0197)

(A)

ME-00175

5) Check the piston pin snap ring for distortion, cracks and wear.

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3) Fit the piston ring straight into the piston ring groove, then measure the clearance between piston ring and piston ring groove with a thickness gauge. NOTE: Before measuring the clearance, clean the piston ring groove and piston ring. Standard mm (in) Clearance between piston ring and piston ring groove

Top ring Second ring

Clearance between oil ring and oil ring groove

5. CONNECTING ROD 1) Replace the connecting rod, if the large or small end thrust surface is damaged. 2) Check for bend or twist using a connecting rod aligner. Replace the connecting rod if it has the bend or twist.

Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in)

0.040 — 0.080 (0.0016 — 0.0031)

(A)

0.030 — 0.070 (0.0012 — 0.0028) 0.065 — 0.165 (0.0026 — 0.0065)

(B)

(A) ME-00178 (B)

ME-00179

(A) Thickness gauge (B) Connecting rod

3) Install the connecting rod with bearings attached to the crankshaft, and using a thickness gauge, measure the thrust clearance. If the thrust clearance exceeds the standard or uneven wear is found, replace the connecting rod.

Connecting rod thrust clearance: Standard 0.070 — 0.330 mm (0.0028 — 0.0130 in)

ME-00180

4) Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc.

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Cylinder Block MECHANICAL

5) Measure the oil clearance on each connecting rod bearing using plastigauge. If any oil clearance is not within the standard, replace the defective bearing with a new part of standard size or undersize as necessary. (See the table below.)

Connecting rod oil clearance: Standard 0.016 — 0.043 mm (0.0006 — 0.0017 in) Bearing

Bearing size (Thickness at center)

Unit: mm (in) Outer diameter of crank pin

Standard

1.489 — 1.505 (0.0586 — 0.0593)

51.976 — 52.000 (2.0463 — 2.0472)

0.03 (0.0012) Undersize

1.507 — 1.515 (0.0593 — 0.0596)

51.954 — 51.970 (2.0454 — 2.0461)

1.517 — 1.525 (0.0597 — 0.0600)

51.934 — 51.950 (2.0446 — 2.0453)

1.617 — 1.625 (0.0637 — 0.0640)

51.734 — 51.750 (2.0368 — 2.0374)

0.05 (0.0020) Undersize 0.25 (0.0098) Undersize

6) Inspect the bushing at connecting rod small end, and replace with a new part if worn or damaged. 7) Measure the piston pin clearance at connecting rod small end. Replace it with a new part if the value is not within the standard,

8) The replacement procedure for the connecting rod small end bushing is as follows. (1) Remove the bushing from connecting rod with ST and press. (2) Apply oil on the periphery of the new bushing, and press the bushing in with the ST. ST 18350AA000 CONNECTING ROD BUSHING REMOVER AND INSTALLER

ST

ME-00597

(3) Make two 3 mm (0.12 in) holes in the pressed bushing to match the pre-manufactured holes on the connecting rod, then ream the inside of the bushing. (4) After completion of reaming, clean the bushing to remove chips.

Clearance between piston pin and bushing: Standard 0 — 0.022 mm (0 — 0.0009 in)

ME-00181

ME-00174

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Cylinder Block MECHANICAL

6. CRANKSHAFT AND CRANKSHAFT BEARING 1) Clean the crankshaft completely, and check it for cracks using liquid penetrant tester. If defective, replace the crankshaft. 2) Check the crankshaft for bend, and repair or replace if needed. If it exceeds the limit, correct or replace it.

Crank journal: Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit (dia.) To 63.742 mm (2.5095 in)

NOTE: If a suitable V-block is not available, using the #1 and #7 crankshaft bearings on cylinder block, position the crankshaft on cylinder block. Then, measure the crankshaft bend using a dial gauge.

Crankshaft bend limit: 0.035 mm (0.0014 in) ME-00184

ME-00598

3) Inspect the crank journal and crank pin for wear. If they are not within the standard, replace the bearing with a suitable (undersize) one, and replace or grind to correct the crankshaft as necessary. When grinding the crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used.

Crank pin: Out-of-roundness 0.005 mm (0.0002 in) Cylindricality 0.006 mm (0.0002 in) Grinding limit (dia.) To 51.734 mm (2.0368 in)

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Cylinder Block MECHANICAL Unit: mm (in) Crank journal diameter #1, #3, #5

Crank pin outer diameter

Bearing size (Thickness at center)

#7 #2, #4, #6 63.992 — 64.016 (2.5194 — 2.5203) 1.996 — 2.013 1.992 — 2.009 1.996 — 2.013 (0.0786 — 0.0793) (0.0784 — 0.0791) (0.0786 — 0.0793)

Journal O.D. 0.03 (0.0012) Undersize Bearing size (Thickness at center)

63.962 — 63.978 (2.5182 — 2.5188) 2.011 — 2.014 2.011 — 2.014 2.015 — 2.018 (0.0792 — 0.0793) (0.0792 — 0.0793) (0.0793 — 0.0794)

51.954 — 51.970 (2.0454 — 2.0461) 1.507 — 1.515 (0.0593 — 0.0596)

Journal O.D. Standard

51.976 — 52.000 (2.0463 — 2.0472) 1.489 — 1.505 (0.0586 — 0.0593)

Journal O.D. 0.05 (0.0020) Undersize Bearing size (Thickness at center)

63.942 — 63.958 (2.5174 — 2.5180)

51.934 — 51.950 (2.0446 — 2.0453)

2.021 — 2.024 2.021 — 2.024 2.025 — 2.028 (0.0796 — 0.0797) (0.0796 — 0.0797) (0.0797 — 0.0798)

1.517 — 1.525 (0.0597 — 0.0600)

Journal O.D. 0.25 (0.0098) Undersize Bearing size (Thickness at center)

63.742 — 63.758 (2.5095 — 2.5102) 2.121 — 2.124 2.121 — 2.124 2.125 — 2.128 (0.0835 — 0.0836) (0.0835 — 0.0836) (0.0837 — 0.0838)

51.734 — 51.750 (2.0368 — 2.0374) 1.617 — 1.625 (0.0637 — 0.0640)

4) Use a thickness gauge to measure the thrust clearance of crankshaft at center bearing. If clearance exceeds the standard, replace the bearing.

Crankshaft thrust clearance: Standard 0.030 — 0.115 mm (0.0012 — 0.0045 in)

ME-00600

5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting and wear. 6) Measure the oil clearance on each crankshaft bearing using plastigauge. If the measured value is out of standard, replace the defective bearing with an undersize one, and replace or grind to correct the crankshaft as necessary.

Crankshaft oil clearance: Standard 0.010 — 0.030 mm (0.0004 — 0.0012 in)

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Oil Flow Control Solenoid Valve MECHANICAL

21.Oil Flow Control Solenoid Valve A: REMOVAL Specifications for the oil flow control solenoid valve are included in the FU section.

B: INSTALLATION Specifications for the oil flow control solenoid valve are included in the FU section.

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Intake and Exhaust Valve MECHANICAL

22.Intake and Exhaust Valve A: SPECIFICATION Refer to “Cylinder Head” for removal and installation procedures of the intake and exhaust valves.

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Piston MECHANICAL

23.Piston A: SPECIFICATION Refer to “Cylinder Block” for removal and installation procedures of pistons.

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Connecting Rod MECHANICAL

24.Connecting Rod A: SPECIFICATION Refer to “Cylinder Block” for removal and installation procedures of connecting rods.

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Crankshaft MECHANICAL

25.Crankshaft A: SPECIFICATION Refer to “Cylinder Block” for removal and installation procedures of the crankshaft.

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Engine Trouble in General MECHANICAL

26.Engine Trouble in General A: INSPECTION NOTE: The “RANK” shown in the chart shows the possibilities of the cause of trouble in order from “Very often” to “Rarely”. A — Very often B — Sometimes C — Rarely Symptoms 1. Engine does not start. 1) Starter does not turn.

2) Initial combustion does not occur.

Problem parts etc. Starter

Possible cause

Defective battery-to-starter harness Defective starter switch Defective inhibitor switch Defective starter Battery Improper connection of terminal Run-down battery Defective charging system Friction Seizure of crankshaft and connecting rod bearing Seized camshaft Seized or stuck piston and cylinder Starter Defective starter Engine control system Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing chain Trouble Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity)

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RANK B C C B A A B C C C C A A C B B B C C C C C B C B B

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Engine Trouble in General MECHANICAL Symptoms 3) Initial combustion occurs.

4) Engine stalls after initial combustion.

Problem parts etc. Possible cause Engine control system Intake system Defective intake manifold gasket Defective throttle body gasket Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing chain Trouble Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element Fuel line Clogged fuel line Lack of fuel or insufficient fuel Timing chain Trouble Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity)

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RANK A B B C C B B B C C C C C B C B B A B C C B B C C B B B C C C C C B C B B

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Engine Trouble in General MECHANICAL Symptoms 2. Rough idle and engine stall

Problem parts etc. Possible cause Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing chain Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Defective rocker cover gasket Cooling system Over-heating Others Evaporative emission control system malfunction Stuck or damaged throttle valve

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RANK A A A A B B C B C C C B C B B B B C B B A B B C C A B

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Engine Trouble in General MECHANICAL Symptoms 3. Low output, hesitation and poor acceleration

Problem parts etc. Possible cause Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing chain Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Defective rocker cover gasket Cooling system Over-heating Over-cooling Others Evaporative emission control system malfunction

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RANK A A A B B B B B A B B C B B B B B C B C A B B C C C A

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Engine Trouble in General MECHANICAL Symptoms 4. Surging

5. Engine does not return to idle. 6. Dieseling (Run-on)

7. After burning in exhaust system

Problem parts etc. Possible cause Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of fuel or insufficient fuel Timing chain Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Cooling system Over-heating Others Evaporative emission control system malfunction Engine control system Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve Engine control system Cooling system Over-heating Others Evaporative emission control system malfunction Engine control system Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective PCV valve Loosened oil filler cap Timing chain Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over-cooling Others Evaporative emission control system malfunction

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RANK A A A A B B B B B B B C B B C C C C C C A B B C A A A A B B A C C B B C B B C C B C C C A C C C

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Engine Trouble in General MECHANICAL Symptoms 8. Knocking

Problem parts etc. Possible cause Engine control system Intake system Loosened oil filler cap Timing chain Defective timing Compression Incorrect valve clearance Incorrect valve timing Cooling system Over-heating 9. Excessive engine oil con- Intake system Loosened or cracked PCV hose sumption Defective PCV valve Loosened oil filler cap Compression Defective valve stem Worn or stuck piston rings, cylinder and piston Lubrication system Loosened oil pump attaching bolts and defective gasket Defective oil filter O-ring Defective crankshaft oil seal Defective rocker cover gasket Loosened oil drain plug or defective gasket Loosened oil pan fitting bolts or defective oil pan 10. Excessive fuel consump- Engine control system tion Intake system Dirty air cleaner element Timing chain Defective timing Compression Incorrect valve clearance Loosened spark plug or defective gasket Loosened cylinder head bolt or defective gasket Improper valve sealing Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over-cooling

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RANK A B B C B A A B C A A B B B B B B A A B B C C B C C B B C C

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Engine Noise MECHANICAL

27.Engine Noise A: INSPECTION Type of sound

Regular clicking sound

Heavy and dull clank

Condition Sound increases as engine speed increases.

Oil pressure is low. Oil pressure is normal.

High-pitched clank

Sound is noticeable when accelerating with an overload condition.

Possible cause • Valve mechanism is defective. • Incorrect valve clearance • Worn camshaft • Broken valve spring • Trouble of valve lifter • Worn camshaft main bearing • Worn connecting rod bearing (large end) Damaged front mount • • • •

Ignition timing advanced Accumulation of carbon inside combustion chamber Wrong heat range of spark plug Improper octane value gasoline

Noise is reduced when fuel • Worn crankshaft main bearing Clank when engine speed is injector connector of noisy cyl- • Worn connecting rod bearing (large end) between 1,000 and 2,000 rpm. inder is disconnected. * Knocking sound when engine is operating under idling speed and engine is warm Squeaky sound Rubbing sound Gear scream when starting engine

Noise is reduced when fuel • Worn cylinder liner and piston ring injector connector of noisy cyl- • Broken or stuck piston ring inder is disconnected. * • Worn piston pin and hole at piston end of connecting rod • Unusually worn valve lifter Sound is not reduced if each • Worn cam gear fuel injector connector is dis• Worn camshaft journal bore in cylinder head connected in turn. * — Insufficient generator lubrication — Poor contact of generator brush and rotor —

• Defective ignition starter switch • Worn gear and starter pinion

Sound like polishing glass with a dry cloth



• V-belt • Defective water pump shaft

Hissing sound



• Insufficient compression • Air leakage in air intake system, hose, connection or manifold

Timing chain noise



Valve lifter noise



• Loose timing chain • Timing chain contacting with adjacent part Incorrect valve clearance

* When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory. Therefore, perform the Clear Memory Mode and Inspection Mode after connecting the fuel injector connector.

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EXHAUST

EX(H6DO) 1. 2. 3. 4.

Page General Description ...................................................................................2 Front Exhaust Pipe .....................................................................................5 Rear Exhaust Pipe .....................................................................................8 Muffler ........................................................................................................9

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General Description EXHAUST

1. General Description A: COMPONENT 1. FRONT EXHAUST PIPE (22)

(19)

T4

(23)

T1

(15)

(26)

(13)

(18)

(27)

T2

(21) (20)

(17)

T4

T1 (16)

T1

T1

T1

T4 (7)

T3 (6)

T3

(4)

(12)

(14) (11)

(2)

(8)

(1)

(10)

(6)

(3)

T3

(9)

T4

T1

T4 (25)

T3

(5) (23)

(24) (19)

T1

T4

(21)

(15) (20) (17)

T1

T1 (16)

T1

T1 EX-02586

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General Description EXHAUST (1) (2)

Front exhaust pipe (RH) Front catalytic converter (RH)

(12) (13)

Front oxygen sensor (LH) Bracket

(23) (24)

(3)

Rear catalytic converter (RH)

(14)

Protector

(25)

(4) (5) (6) (7)

Rear oxygen sensor (RH) Front oxygen sensor (RH) Gasket Gasket

(15) (16) (17) (18)

(26) (27)

(8) (9)

Front exhaust pipe (LH) Front catalytic converter (LH)

(19) (20)

(10) (11)

Rear catalytic converter (LH) Rear oxygen sensor (LH)

(21) (22)

Front exhaust pipe cover (RH) Front exhaust pipe cover (LH) Clamp Front exhaust pipe upper cover (RH) (front) Catalytic converter upper cover Catalytic converter lower cover (U5 model) Clamp (except for U5 model) Front exhaust pipe upper cover (RH) (rear)

Clamp Front exhaust pipe upper cover (LH) (front) Front exhaust pipe upper cover (LH) (rear) Gasket Spring

Tightening torque:N·m (kgf-m, ft-lb) T1: 13 (1.3, 9.6) T2: 18 (1.8, 13.3) T3: 21 (2.1, 15.5) T4: 30 (3.1, 22.1)

2. REAR EXHAUST PIPE AND MUFFLER

(6)

(10)

(12)

T1 (9) (8)

(1)

(12)

(8)

(9)

T3

(11)

T1

(7)

(6)

(9)

(3)

(7)

T2

T3 (5) (4)

(2)

EX-02587

(1) (2) (3)

Front exhaust pipe (LH) Gasket Spring

(7) (8) (9)

(4) (5) (6)

Chamber Rear exhaust pipe Cushion rubber (with protrusion)

(10) (11) (12)

Self-locking nut Gasket Cushion rubber (without protrusion) Muffler (RH) Muffler (LH) Muffler cutter

EX(H6DO)-3

Tightening torque:N·m (kgf-m, ft-lb) T1: 7.5 (0.8, 5.5) T2: 18 (1.8, 13.3) T3: 48 (4.9, 35.4)

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General Description EXHAUST

B: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery. • If any fat adheres to the exhaust pipe, wipe it off. Otherwise a fire may happen.

EX(H6DO)-4

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Front Exhaust Pipe EXHAUST

2. Front Exhaust Pipe

CAUTION: Be careful not to drop the front exhaust pipe assembly.

A: REMOVAL CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the under cover. 4) Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).

EX-02538

7) Remove the bolt which holds front exhaust pipe assembly to hanger bracket. (B)

(A)

EX-02539

8) Remove the front exhaust pipe assembly. (B)

(A)

EX-02588

5) Remove the rear exhaust pipe from the front exhaust pipe assembly.

CAUTION: • Be careful not to let the front exhaust pipe assembly fall off when removing, since it is very heavy. • After removing the front exhaust pipe assembly, do not apply excessive pulling force on the rear exhaust pipe. 9) Separate the front exhaust pipe (RH) from the front exhaust pipe (LH).

EX-02572 EX-02537

6) Remove the nuts which hold front exhaust pipe assembly onto cylinder heads.

10) Remove the front oxygen (A/F) sensor and rear oxygen sensor.

EX(H6DO)-5

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Front Exhaust Pipe EXHAUST

B: INSTALLATION 1) Install the front oxygen (A/F) sensor and rear oxygen sensor. 2) Install the front exhaust pipe (RH) to the front exhaust pipe (LH).

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

NOTE: Use a new gasket.

Tightening torque: 30 N·m (3.1 kgf-m, 22.1 ft-lb)

EX-02537

6) Tighten the bolts which hold front exhaust pipe assembly to hanger bracket.

Tightening torque: 30 N·m (3.1 kgf-m, 22.1 ft-lb)

EX-02572

3) Install the front exhaust pipe assembly. NOTE: Use a new gasket. 4) Temporarily tighten the nuts which hold front exhaust pipe assembly to cylinder heads.

EX-02539

7) Tighten the nuts which hold the front exhaust pipe assembly to the cylinder heads in the numerical sequence as shown in the figure.

Tightening torque: 30 N·m (3.1 kgf-m, 22.1 ft-lb)

(1)

(8) (9)

(6)

(4)

(2)

(7)

(5)

(3)

EX-02538

5) Install the front exhaust pipe assembly to the rear exhaust pipe. NOTE: Use a new gasket.

(10)

EX-02573

EX(H6DO)-6

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Front Exhaust Pipe EXHAUST

8) Connect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).

(B)

(A)

(B)

(A)

EX-02588

9) Install the under cover. 10) Lower the vehicle. 11) Connect the ground cable to battery.

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting.

EX(H6DO)-7

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Rear Exhaust Pipe EXHAUST

3. Rear Exhaust Pipe A: REMOVAL CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Lift up the vehicle. 2) Remove the rear exhaust pipe from the front exhaust pipe assembly.

NOTE: After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.

EX-02541

3) Install the rear exhaust pipe to the muffler. NOTE: Use a new gasket and self-locking nut. EX-02537

Tightening torque: 48 N·m (4.9 kgf-m, 35.4 ft-lb)

3) Remove the rear exhaust pipe from the muffler. CAUTION: Be careful not to drop the rear exhaust pipe.

EX-02540

4) Install the rear exhaust pipe to the front exhaust pipe assembly. EX-02540

4) Apply a coat of spray type lubricant to the mating area of cushion rubber. 5) Remove the rear exhaust pipe from the cushion rubber.

NOTE: Use a new gasket.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

EX-02537 EX-02541

5) Lower the vehicle.

B: INSTALLATION

C: INSPECTION

1) Apply a coat of spray type lubricant to the mating area of cushion rubber. 2) Install the rear exhaust pipe to the cushion rubber.

1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting. 3) Check the cushion rubber for wear or crack.

EX(H6DO)-8

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Muffler EXHAUST

4. Muffler

Tightening torque: 48 N·m (4.9 kgf-m, 35.4 ft-lb)

A: REMOVAL CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. 1) Lift up the vehicle. 2) Remove the muffler from rear exhaust pipe.

EX-02540

C: INSPECTION 1) Check the connections and welds for exhaust leaks. 2) Make sure there are no holes or rusting. 3) Check the cushion rubber for wear or crack. EX-02540

3) Apply a coat of spray type lubricant to the mating area of cushion rubber. 4) Remove the muffler from the cushion rubber. CAUTION: Be careful not to drop the muffler during removal.

EX-02542

B: INSTALLATION Install in the reverse order of removal. NOTE: • Use a new gasket and self-locking nut. • After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.

EX(H6DO)-9

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Muffler EXHAUST

EX(H6DO)-10

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COOLING

CO(H6DO) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Page General Description ...................................................................................2 Radiator Fan System .................................................................................8 Engine Coolant .........................................................................................12 Water Pump .............................................................................................14 Thermostat ...............................................................................................15 Radiator ....................................................................................................17 Radiator Cap ............................................................................................20 Radiator Main Fan and Fan Motor ...........................................................21 Radiator Sub Fan and Fan Motor .............................................................24 Reservoir Tank .........................................................................................25 Radiator Fan Control Unit ........................................................................26 Engine Cooling System Trouble in General .............................................27

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General Description COOLING

1. General Description A: SPECIFICATION Electric fan + Forced engine coolant circulation system 2 (US qt, Imp qt) 6.5 (6.9, 5.7) Centrifugal impeller type

Cooling system Total engine coolant capacity Type

Water pump

Thermostat

Discharge rate

Discharge performance

240 (63.4, 52.8)

Pump speed — Discharge pressure Engine coolant temperature Impeller diameter mm (in) Number of impeller blades Pump sprocket outer diameter mm (in) Type Starting temperature to open Fully opens Valve lift mm (in) Valve bore mm (in) Motor input

Main fan Sub fan

Fan diameter / Blade

Main fan Sub fan

Radiator fan

Type Core dimensions

Radiator

2 (US gal, Imp gal) /min.

Pressure range in which cap valve is open

4,956 rpm — 140 kPa (14.0 mAq) 80°C (176°F) 66 (2.60) 8 60.60 (2.39) Wax pellet type 80 — 84°C (176 — 183°F) 95°C (203°F) 9.0 (0.354) or more 35 (1.38)

W W

200 200 320 mm (12.6 in)/5 320 mm (12.6 in)/7 Down flow, pressure type 689.8 × 349.2 × 16 (27.16 × 13.75 × 0.63)

Width × Height × Thickness

mm (in)

Positive pressure side

Standard Service limit

93 — 123 (0.95 — 1.25, 14 — 18)

Negative pressure side

Standard

–1.0 — –4.9 (–0.01 — –0.05, –0.1 — –0.7)

kPa (kg/cm2, psi)

83 (0.85, 12)

Fins Reservoir tank

Corrugated fin type

Capacity

Coolant Water for dilution Cooling system protecting agent

2 (US qt, Imp qt)

Recommended materials SUBARU Super Coolant (Concentrated type) SUBARU Super Coolant (Diluted type)

0.45 (0.48, 0.40)

Item number

Alternative

— — K0670Y0001

Distilled water



Soft water or tap water

Cooling system conditioner

SOA345001



CO(H6DO)-2

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General Description COOLING

B: COMPONENT 1. WATER PUMP AND WATER PIPE

(6)

T2

(4) (5)

T1 (3)

T1

(2)

(9)

(1)

T2

(8)

(7)

CO-02659

(1) (2) (3) (4) (5)

Water pump ASSY O-ring Thermostat Gasket Thermostat cover

(6) (7) (8) (9)

Oil pan upper Clamp Hose Water return pipe

CO(H6DO)-3

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 16 (1.6, 11.8)

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General Description COOLING

2. ENGINE COOLANT TEMPERATURE SENSOR AND HEATER HOSE (3) T2

(A) T1

(4)

T1 T1

(1) (5)

(B) (5) (2)

(5)

(C)

CO-02609

(A)

To the throttle body

(B)

To the heater hose on body side

(1) (2) (3)

Heater pipe Preheater hose Engine coolant temperature sensor

(4) (5)

Gasket Clamp

CO(H6DO)-4

(C)

To the throttle body

Tightening torque:N·m (kgf-m, ft-lb) T1: 19 (1.9, 14.0) T2: 22 (2.2, 16.2)

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General Description COOLING

3. RADIATOR AND RADIATOR FAN • Radiator

T

(2)

(4) (11)

(3)

(12)

(5)

(1)

(5) (5)

(5) B

(5) (5)

(5) (10)

(6)

(9)

(5) (7) B A A

(5)

(13)

(5) (8) CO-02604

(1) (2) (3) (4) (5) (6)

Radiator Radiator upper bracket Radiator upper cushion Radiator upper hose RH Clamp Radiator upper hose LH

(7) (8) (9) (10) (11)

Radiator lower hose Radiator lower cushion Drain plug ATF hose A ATF pipe B

CO(H6DO)-5

(12) (13)

ATF pipe A ATF hose B

Tightening torque:N·m (kgf-m, ft-lb) T: 12 (1.2, 8.9)

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General Description COOLING

• Radiator fan (1)

T1 (5)

(3)

(4) (2) (6)

T4

(7) T2 T2

(10) (8)

T3

(9) T3

CO-02628

(1) (2) (3) (4) (5)

Radiator fan control unit Radiator fan harness Radiator sub fan motor Radiator main fan motor Over flow hose

(6) (7) (8) (9) (10)

Reservoir tank cap Reservoir tank Radiator fan shroud Radiator main fan Radiator sub fan

CO(H6DO)-6

Tightening torque:N·m (kgf-m, ft-lb) T1: 2.6 (0.3, 1.9) T2: 3.8 (0.4, 2.8) T3: 6.3 (0.6, 4.6) T4: 7.5 (0.8, 5.5)

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General Description COOLING

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. • Prepare a container and cloth to prevent scattering of engine coolant when performing work where engine coolant can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing engine coolant.

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 1B022XU0

DESCRIPTION SUBARU SELECT MONITOR III KIT

REMARKS Used for troubleshooting the electrical system.

ST1B022XU0

2. GENERAL TOOL TOOL NAME Circuit tester Radiator cap tester

REMARKS Used for measuring resistance and voltage. Used for checking radiator and radiator cap.

CO(H6DO)-7

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Radiator Fan System COOLING

2. Radiator Fan System A: WIRING DIAGRAM

MB-5 SBF-2 (B)

FB-35 F/B FUSE NO. 26 (IG)

2

1

TO POWER SUPPLY CIRCUIT

A/C RELAY HOLDER B497

4

3

1

1

3

2

3

4

MAIN FAN RELAY

B504

RADIATOR FAN CU

2

1

2

1

F106

F17

F16

4

J/C 11

B135

12

B478

REF. TO GND [GND-02] MAIN FAN MOTOR

ECM

SUB FAN MOTOR

B497 F16 F17 1 2

F106

B504

1 2 3

1 2 3

4

B478 1 2 3 4 5

B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

1 2

3 4

7 5 6 8 9

12 10 11 13 14

15

17

16

18

CO-02651

CO(H6DO)-8

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Radiator Fan System COOLING

B: RADIATOR FAN CONTROL OUTPUT WAVEFORM

(V)

(A)

0

CO-02117

(A)

5V

C: INSPECTION Operating condition: Radiator fan operates depending on the radiator fan speed related to engine coolant temperature or the radiator fan speed related to A/C compressor load, whichever is higher as a load condition. • Radiator fan speed related to engine coolant temperature

(A) 100

70

30

(1) (2)

(3)

(4)

(5)

(B) CO-02657

(A) (B)

Radiator fan speed (%) Engine coolant temperature

(1) (2) (3) (4) (5)

95°C (203°F) 96°C (205°F) 98°C (208°F) 100°C (212°F) 101°C (214°F)

CO(H6DO)-9

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Radiator Fan System COOLING

• Radiator fan speed related to A/C compressor load

(A) 100

70

30

(1)

(2)

(4)

(3)

(5)

(B) CO-02658

(A) (B)

Radiator fan speed (%) A/C compressor refrigerant pressure

(1) (2) (3) (4) (5)

0.8 MPa (8.16 kgf/cm2, 116 psi) 1.0 MPa (10.20 kgf/cm2, 145 psi) 1.5 MPa (15.30 kgf/cm2, 218 psi) 4.0 MPa (40.79 kgf/cm2, 580 psi) 5.0 MPa (50.98 kgf/cm2, 725 psi)

DIAGNOSIS: Radiator main and sub fans do not rotate under the above conditions. 1

2

3

Step CHECK MAIN FAN RELAY. 1) Turn the ignition switch to OFF. 2) Remove the main fan relay from the relay holder. 3) Measure the resistance between main fan relay switch terminals. CHECK MAIN FAN RELAY. 1) Connect the battery to the terminal on main fan relay coil side. 2) Measure the resistance between main fan relay switch terminals. CHECK POWER SUPPLY FOR ECM. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM terminal and chassis ground. Connector & terminal (B135) No. 12 (+) — Chassis ground (–):

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Replace the main fan relay.

Is the resistance less than 1 Ω? Go to step 3.

Replace the main fan relay.

Go to step 4.

Repair the power supply line.

Is the voltage 10 V or more?

CO(H6DO)-10

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Radiator Fan System COOLING

4

5

6

7

8

9

Step CHECK POWER SUPPLY FOR RADIATOR FAN CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Connect the connector to ECM. 3) Disconnect the connector from radiator fan control unit. 4) Turn the ignition switch to ON. 5) Measure the voltage between radiator fan control unit terminal and chassis ground. Connector & terminal (F106) No. 3 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND RADIATOR FAN CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM. 3) Measure the resistance between radiator fan control unit and ECM connector. Connector & terminal (B135) No. 11 — (F106) No. 2: CHECK RADIATOR FAN CONTROL UNIT AND GROUND CIRCUIT. 1) Connect the connector to ECM and radiator fan control unit. 2) Measure the resistance between radiator fan control unit connector and chassis ground. Connector & terminal (F106) No. 1 — Chassis ground: CHECK MAIN FAN MOTOR. 1) Disconnect the connector from radiator fan control unit. 2) Connect the battery positive (+) terminal to terminal No. 1 of the main fan motor, and the ground (–) terminal to terminal No. 2. CHECK SUB FAN MOTOR. 1) Disconnect the connector from radiator fan control unit. 2) Connect the battery positive (+) terminal to terminal No. 1 of the sub fan motor, and the ground (–) terminal to terminal No. 2. CHECK OUTPUT SIGNAL FROM ECM. 1) Turn the ignition switch to OFF. 2) Connect the delivery mode fuse. 3) Turn the ignition switch to ON. 4) Check the output waveform using oscilloscope. Connector & terminal (B135) No. 11 (+) — Chassis ground (–):

Check Is the voltage 10 V or more?

Yes Go to step 5.

No Repair the power supply line.

Is the resistance less than 1 Ω? Go to step 6.

Repair the open circuit of harness between ECM and radiator fan control unit.

Is the resistance less than 5 Ω? Go to step 7.

Repair the open circuit of harness between radiator fan control unit connector and chassis ground.

Does the main fan motor rotate?

Replace the main fan motor.

Go to step 8.

Does the sub fan motor rotate? Go to step 9.

Replace the sub fan motor.

Is waveform being output?

Replace the ECM.

CO(H6DO)-11

Replace the radiator fan control unit.

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Engine Coolant COOLING

3. Engine Coolant A: REPLACEMENT 1. DRAINING OF ENGINE COOLANT 1) Lift up the vehicle. 2) Remove the under cover. 3) Remove the drain plug to drain engine coolant into container.

NOTE: The SUBARU Super Coolant is especially made for SUBARU engine, which has an aluminum cylinder block, and contains anti-freeze and anti-rust agents. Always use SUBARU Super Coolant, since other coolant may cause corrosion. 3) Fill engine coolant into the reservoir tank up to “FULL” level.

NOTE: Remove the radiator cap so that engine coolant will drain faster.

(A) (B)

CO-02611

(A) FULL (B) LOW

CO-02610

4) Install the drain plug. 5) Install the under cover.

2. FILLING OF ENGINE COOLANT 1) Pour cooling system conditioner from the filler neck of the radiator.

Cooling system protecting agent: Refer to “SPECIFICATION” for cooling system protecting agent. 2) Pour engine coolant into the radiator up to the filler neck position. Recommended engine coolant: Refer to “SPECIFICATION” for recommended engine coolant. Engine coolant level: Refer to “SPECIFICATION” for engine coolant level. Engine coolant concentration: Refer to “ADJUSTMENT” for the recommended engine coolant concentration.

4) Close the radiator cap and start the engine. Race 5 to 6 times at 3,000 rpm or less, then stop the engine. (Complete this operation within 40 seconds.) 5) Wait for one minute after the engine stops, and open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position. 6) Perform the procedures 4) and 5) again. 7) Attach the radiator cap and reservoir tank cap properly. 8) Start the engine and operate the heater at maximum hot position and the blower speed setting to “LO”. 9) Run the engine at 2,000 rpm or less until radiator fan starts and stops. NOTE: • Be careful with the engine coolant temperature gauge to prevent overheating. • If the radiator hose becomes hardened with the pressure of engine coolant, air bleeding operation seems to be almost completed. 10) Stop the engine and wait until the engine coolant temperature lowers to 30°C (86°F) or less. 11) Open the radiator cap. If the engine coolant level drops, fill engine coolant up to the radiator filler neck position and to the reservoir tank “FULL” level. 12) Attach the radiator cap and reservoir tank cap properly. 13) Set the heater setting to maximum hot position and the blower speed setting to “LO” and start the engine. Perform racing at 3,000 rpm or less. If the flowing sound is heard from heater core, repeat the procedures from step 9).

CO(H6DO)-12

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Engine Coolant COOLING

B: ADJUSTMENT 1. PROCEDURE TO ADJUST THE SUBARU SUPER COOLANT CONCENTRATION CAUTION: Use the SUBARU Super Coolant with a 50 — 60% concentration in order to obtain maximum antifreeze and anti-rust performance. To adjust the concentration of SUBARU Super Coolant according to temperature, find the proper SUBARU Super Coolant concentration in the table, and add diluting water to the SUBARU Super Coolant (concentrated type) until it reaches the proper dilution. Relationship of Subaru Super Coolant concentration and freezing temperature SUBARU Super Coolant concentration 50% 55% Freezing temperature –36°C (–33°F) –41°C (–42°F)

60% –50°C (–58°F)

Engine coolant and diluting water: Refer to “SPECIFICATION” for the recommended engine coolant and diluting water.

CO(H6DO)-13

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Water Pump COOLING

4. Water Pump A: REMOVAL 1) Remove the radiator. 2) Remove the V-belts. 3) Remove the crank pulley. 4) Remove the chain cover. 5) Remove the timing chain assembly. 6) Remove the water pump from the oil pan upper.

6) Install the radiator. 7) Fill engine coolant.

C: INSPECTION 1) Check the water pump bearing for smooth rotation. 2) Check the water pump sprocket for abnormalities. 3) Make sure the impeller is not abnormally deformed or damaged. 4) After water pump installation, check pulley shaft for engine coolant leaks or noise. If leaks or noise are noted, replace the water pump assembly.

CO-02376

B: INSTALLATION 1) Tighten the bolts in the numerical order as shown in the figure, and install water pump to the oil pan upper. NOTE: Use new O-rings.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) (3) (5) (6)

(2) (4)

(1)

CO-02377

2) Install the timing chain assembly. 3) Install the chain cover. 4) Install the crank pulley. 5) Install the V-belts.

CO(H6DO)-14

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Thermostat COOLING

5. Thermostat

3) Install the radiator lower hose to the radiator lower and the thermostat cover.

A: REMOVAL 1) Lift up the vehicle. 2) Remove the under cover. 3) Drain engine coolant completely. 4) Remove the radiator lower hose from the radiator lower and the thermostat cover.

CO-02612

4) Install the under cover. 5) Lower the vehicle. 6) Fill engine coolant.

C: INSPECTION CO-02612

5) Remove the thermostat cover, and then remove the thermostat.

CO-02613

B: INSTALLATION 1) Install a gasket to thermostat. NOTE: Use a new gasket. 2) Install the thermostat and thermostat cover. NOTE: Install the parts with the jiggle pin facing the upside.

1) Check that the thermostat does not have deformation, cracks or damage. 2) Check that the thermostat valve closes completely at an ambient temperature. 3) Immerse the thermostat and a thermometer in water. Raise water temperature gradually, and check the temperature and valve lift when the valve begins to open and when the valve is fully opened. Replace the thermostat if faulty. NOTE: • During the test, agitate the water for even temperature distribution. • Leave the thermostat in the boiling water for five minutes or more before measuring the valve lift. • Hold the thermostat with a wire or the like to avoid contacting the container.

Starting temperature to open: 80 — 84°C (176 — 183°F) Full open temperature: 95°C (203°F)

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

CO-02613

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Thermostat COOLING

Total valve lift: 9.0 mm (0.354 in) or more

(A)

(B)

CO-02420

(A) Thermometer (B) Thermostat

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Radiator COOLING

6. Radiator

7) Disconnect the radiator lower hose from the radiator lower.

A: REMOVAL CAUTION: The radiator is pressurized when the engine and radiator are hot. Wait until engine and radiator cools down before working on the radiator. 1) Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. (1) Lift up (A) in two positions at the rear. (2) Moving (B) in two positions at the front toward the vehicle, lift them up.

(A)

8) Lower the vehicle. 9) Remove the air intake duct. 10) Remove the grille bracket. NOTE: Remove ten clips when removing the grille bracket.

(A)

(B)

CO-02597

(B) ME-04447

2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Remove the under cover. 5) Drain engine coolant completely. 6) Disconnect the integrated connector of radiator main fan & fan motor and radiator sub fan & fan motor.

CO-02594

11) Remove the radiator main fan & fan motor and radiator sub fan & fan motor. 12) Disconnect the ATF hoses A and B from the radiator. NOTE: Plug the ATF hoses A and B to prevent ATF from leaking.

CO-02593

CO-02596

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Radiator COOLING

13) Remove the radiator upper brackets.

5) Attach the grille bracket.

CO-02595

14) Lift the radiator up and away from vehicle. 15) Remove the radiator lower cushion.

B: INSTALLATION 1) Install the radiator lower cushion. 2) Install the radiator to vehicle. NOTE: Insert pins on the lower side of radiator into the radiator lower cushions on vehicle side. 3) Install the radiator upper brackets.

CO-02594

6) Install the radiator main fan & fan motor and radiator sub fan & fan motor. 7) Lift up the vehicle. 8) Connect the radiator lower hose to the radiator lower.

Tightening torque: 12 N·m (1.2 kgf-m, 8.9 ft-lb)

CO-02597

9) Connect the integrated connector of radiator main fan & fan motor and radiator sub fan & fan motor. CO-02595

4) Connect the ATF hoses A and B. NOTE: Use a new ATF hose.

CO-02593

CO-02596

10) Install the under cover. 11) Lower the vehicle. 12) Connect the ground cable to battery. 13) Fill engine coolant. 14) Check the ATF level and replenish it if necessary. 15) Install the air intake duct.

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Radiator COOLING

16) Install the collector cover.

C: INSPECTION 1) Check that the radiator does not have deformation, cracks or damage. 2) Check that the hose has no cracks, damage or loose part. 3) Remove the radiator cap, fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator. 4) Apply a pressure of 157 kPa (1.6 kgf/cm2, 23 psi) to the radiator, and check the following items. • Leakage from the radiator or its vicinity • Leakage from the hose or its connections CAUTION: • Engine should be turned off. • Wipe engine coolant from check points in advance. • Be careful of engine coolant from spurting out when removing the radiator cap tester. • Be careful not to deform the filler neck of radiator when installing and removing the radiator cap tester.

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Radiator Cap COOLING

7. Radiator Cap A: INSPECTION 1) Check that the radiator cap does not have deformation, cracks or damage. 2) Attach the radiator cap tester to radiator cap.

CO-00044

3) Increase pressure until the radiator cap tester gauge needle stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 — 6 seconds. Replace the radiator cap if its valve opens at less than the service limit.

Standard: 93 — 123 kPa (0.95 — 1.25 kgf/cm2, 14 — 18 psi) Service limit: 83 kPa (0.85 kgf/cm2, 12 psi) CAUTION: Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect.

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Radiator Main Fan and Fan Motor COOLING

8. Radiator Main Fan and Fan Motor

NOTE: Remove ten clips when removing the grille bracket.

A: REMOVAL 1) Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. (1) Lift up (A) in two positions at the rear. (2) Moving (B) in two positions at the front toward the vehicle, lift them up.

(A)

10) Remove the reservoir tank. 11) Remove radiator upper hoses LH and RH only on radiator side.

(A)

(B)

CO-02594

(B) ME-04447

2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Remove the under cover. 5) Drain engine coolant completely. 6) Disconnect the integrated connector of radiator main fan & fan motor and radiator sub fan & fan motor.

CO-02605

12) Remove the ATF hose from the clip of radiator fan shroud. 13) Remove bolts on the upper side of radiator fan shroud.

CO-02606 CO-02593

7) Lower the vehicle. 8) Remove the air intake duct. 9) Remove the grille bracket.

CO-02614

14) Remove the radiator fan shroud.

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Radiator Main Fan and Fan Motor COOLING

NOTE: When pulling up the radiator fan shroud, be careful not to damage the radiator hose or ATF hose.

4) Attach the grille bracket.

B: INSTALLATION 1) Tighten the bolts on the upper side of radiator fan shroud.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) CO-02594

5) Install the air intake duct. 6) Lift up the vehicle. 7) Connect the integrated connector of radiator main fan & fan motor and radiator sub fan & fan motor. CO-02606

CO-02593

CO-02614

2) Install radiator upper hoses LH and RH to the radiator.

8) Install the under cover. 9) Lower the vehicle. 10) Fill engine coolant. 11) Connect the ground cable to battery. 12) Install the collector cover.

C: DISASSEMBLY 1) Disconnect the connector from the radiator fan control unit, and remove the harness. CO-02605

3) Install the reservoir tank.

CO-02601

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Radiator Main Fan and Fan Motor COOLING

E: INSPECTION

2) Remove the radiator main fan.

Check that the radiator main fan, radiator main fan shroud and main fan motor do not have deformation, cracks or damage.

CO-02599

3) Remove the radiator main fan motor.

CO-02600

D: ASSEMBLY Assemble in the reverse order of disassembly.

Tightening torque: 3.8 N·m (0.4 kgf-m, 2.8 ft-lb)

CO-02600

Tightening torque: 6.3 N·m (0.6 kgf-m, 4.6 ft-lb)

CO-02599

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Radiator Sub Fan and Fan Motor COOLING

9. Radiator Sub Fan and Fan Motor

D: ASSEMBLY

A: REMOVAL

Tightening torque: 3.8 N·m (0.4 kgf-m, 2.8 ft-lb)

Refer to the Radiator Main Fan and Fan Motor.

Assemble in the reverse order of disassembly.

B: INSTALLATION Refer to the Radiator Main Fan and Fan Motor.

C: DISASSEMBLY 1) Disconnect the connector from the radiator fan control unit, and remove the harness.

CO-02603

Tightening torque: 6.3 N·m (0.6 kgf-m, 4.6 ft-lb)

CO-02598

2) Remove the radiator sub fan.

CO-02602

E: INSPECTION Check that the radiator sub fan, radiator sub fan shroud and sub fan motor do not have deformation, cracks or damage.

CO-02602

3) Remove the radiator sub fan motor.

CO-02603

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Reservoir Tank COOLING

10.Reservoir Tank A: REMOVAL 1) Pull out the over flow hose. 2) Remove bolts which secure the reservoir tank, and remove the reservoir tank.

CO-02570

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

C: INSPECTION 1) Check that the reservoir tank does not have deformation, cracks or damage. 2) Check the over flow hose for cracks or damage. 3) Make sure the engine coolant level is between “FULL” and “LOW”.

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Radiator Fan Control Unit COOLING

11.Radiator Fan Control Unit A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the radiator fan control unit. (1) Disconnect the connector (A) from the radiator fan control unit. (2) Remove screws which secure the radiator fan control unit.

(A) (A)

CO-02571

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 2.6 N·m (0.3 kgf-m, 1.9 ft-lb)

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Engine Cooling System Trouble in General COOLING

12.Engine Cooling System Trouble in General A: INSPECTION Trouble

Possible cause a. Insufficient engine coolant b. Defective thermostat c. Malfunction of water pump d. Clogged engine coolant passage e. Improper ignition timing f. Clogged or leaking radiator g. Defective radiator cap

Over-heating

h. Improper engine oil in engine coolant i. Air/fuel mixture ratio too lean j. Excessive back pressure in exhaust system k. Insufficient clearance between piston and cylinder l. Dragging brake

Noise

Replace the engine coolant. If ineffective, check, repair or replace engine components. Inspect and repair the fuel injection system. Clean or replace. Adjust or replace.

a. Ambient temperature extremely low b. Defective thermostat

Partly cover radiator front area. Replace.

a. Loosened or damaged connecting units on hoses

Repair or replace.

b. Leakage from water pump c. Leakage from water pipe Engine coolant leaks

Replenish engine coolant, inspect for leakage, and repair it if necessary. Replace. Replace. Clean. Inspect and repair the ignition control system. Clean, repair or replace. Replace.

Adjust. Inspect the radiator fan relay, engine coolant temperature sensor or fan motor and replace them.

m. Defective radiator fan Over-cooling

Corrective action

d. Leakage around cylinder head gasket

Replace. Repair or replace. Retighten cylinder head bolts or replace cylinder head gasket.

e. Damaged or cracked cylinder head and cylinder block

Repair or replace.

f. Damaged or cracked thermostat cover g. Leakage from radiator a. Defective radiator fan b. Defective water pump bearing c. Defective water pump mechanical seal

Repair or replace. Repair or replace. Replace. Replace water pump. Replace water pump.

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Engine Cooling System Trouble in General COOLING

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LUBRICATION

LU(H6DO) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Page General Description ...................................................................................2 Oil Pressure System ..................................................................................7 Engine Oil ...................................................................................................9 Oil Pan .....................................................................................................11 Oil Pump ..................................................................................................12 Oil Pressure Switch ..................................................................................14 Engine Oil Filter ........................................................................................15 Oil Cooler .................................................................................................16 Oil Level Switch ........................................................................................17 Engine Lubrication System Trouble in General ........................................24

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General Description LUBRICATION

1. General Description A: SPECIFICATION Lubrication method Pump type Inner rotor Outer rotor Outer rotor diameter × thickness Number of teeth

Oil pump

mm (in) Discharge pressure Discharge rate Discharge pressure Discharge rate

600 rpm Performance (Oil temperature 80°C (176°F)) 6,000 rpm

kPa (kgf/cm2, psi) 2 (US qt, Imp qt)/min. kPa (kgf/cm2, psi) 2 (US qt, Imp qt)/min.

Filter type Filtration area Oil filter

Engine oil

kPa

Type Operating voltage — power consumption Warning light operating pressure Proof pressure Total capacity (at overhaul) When replacing engine oil and oil filter When replacing engine oil only

Recommended oil: Oil corresponding to either of the following standards. • Those with SM “Energy Conserving” logo in case of API standard. • Those with GF-4 “starburst mark” displayed on top of the container in case of ILSAC standard. SAE (1) ( C) -30 -20 -15 ( F) -22 -4 5

98 (1.0, 14) 5.0 (5.3, 4.4) or more 392 (4.0, 57) 82.8 (87.5, 72.9) or more Full-flow filter type

cm2 (sq in)

By-pass valve opening pressure Outer diameter × width Installation screw specifications

Oil pressure switch

Forced lubrication Trochoid type 7 8 76 × 30.2 (2.99 × 1.19)

0

15

30

32

59

86 104

40

10W-30, 10W-40 , 10W-50 5W-30 (2), 5W-40

(kgf/cm2,

psi) mm (in)

kPa (kgf/cm2, psi) kPa (kgf/cm2, psi) 2 (US qt, Imp qt) 2 (US qt, Imp qt) 2 (US qt, Imp qt)

1,300 (201.5) 160 (1.63, 23.2) 80 × 75 (3.15 × 2.95) M 20 × 1.5 Immersed contact point type 12 V — 3.4 W or less 14.7 (0.15, 2.1) 980 (10.0, 142) or more 7.8 (8.2, 6.9) 6.5 (6.9, 5.7) 6.3 (6.7, 5.5)

CAUTION: It is acceptable to fill an engine with oil of another brand when replacing the oil, but make sure to use an oil with an API standard and SAE viscosity number specified by Subaru. NOTE: • The proper viscosity oil helps the engine maintain its ideal temperature, and cranking speed increased by reducing viscosity friction in hot condition. • If the vehicle is used in regions of high temperatures or in other severe environments, use oil with the viscosities shown below. API standard: SM or SL SAE viscosity No.: 30, 40, 10W-50, 20W-40, 20W50

LU-02488

(1) SAE viscosity No. and applicable temperature (2) Recommended

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General Description LUBRICATION

B: COMPONENT 1. OIL PAN UPPER, OIL COOLER, AND OIL FILTER

T7 (4) (4) (1)

(5) (2) (3) (12)

(12)

T8 T9

(13) (12)

(12)

(11)

(11)

(12)

(9)

T5 (13) (14)

(10) T4

(15)

(11) T8

(11) T8

T3

(11)

(11) T8

T8

T5

(4)

T1

(11) (12) T2

(6) (4) (7) (4) (8)

(16)

(4)

(17) T1 T6 (19) (18)

T1

LU-02508

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General Description LUBRICATION (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Oil filter Oil cooler connector Oil cooler Clamp Water hose Water hose Engine oil cooler water pipe Water hose Oil pressure switch harness Oil pressure switch

(11) (12) (13) (14) (15) (16) (17) (18) (19)

PLUG O-ring Stud bolt Oil pan upper Oil level switch Oil pan magnet Oil pan lower Gasket Drain plug

LU(H6DO)-4

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 17 (1.7, 12.5) T3: 23 (2.3, 17.0) T4: 25 (2.5, 18.4) T5: 34 (3.5, 25.1) T6: 44 (4.5, 32.5) T7: 54 (5.5, 39.8) T8: 60 (6.1, 44.3) T9: 90 (9.2, 66.4)

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General Description LUBRICATION

2. OIL PUMP (1) T3

(6) (3)

T4

(2)

(4)

(5)

(7)

T2

T1 LU-02509

(1) (2) (3) (4)

Idler sprocket Oil pan upper O-ring O-ring

(5) (6) (7)

Oil pump Stiffener Strainer

LU(H6DO)-5

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 13 (1.3, 9.6) T3: 24 (2.4, 17.7) T4: 120 (12.2, 88.5)

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General Description LUBRICATION

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Before applying liquid gasket, completely remove the old liquid gasket and degrease it. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery. • If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. • Prepare a container and cloth to prevent scattering of oil when performing work where fuels can be spilled. If the oil spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government and local regulations concerning disposal of refuse when disposing of oil.

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 18332AA020

DESCRIPTION OIL FILTER WRENCH

REMARKS Used for removing and installing oil filter.

ST18332AA020

2. GENERAL TOOL TOOL NAME Circuit tester

REMARKS Used for measuring resistance and voltage.

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Oil Pressure System LUBRICATION

2. Oil Pressure System A: WIRING DIAGRAM TO POWER SUPPLY CIRCUIT

OIL PRESSURE WARNING LIGHT

19

FB-30 F/B FUSE NO. 5 (IG)

COMBINATION METER

35

B36

45

8

i10

B21

E11

OIL PRESSURE SWITCH

i10

B21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

B36

38 45 51

39 52

40 46 53

41 47

1

2

10 11

12

13

14 15 16 17 18 19 20 21 22 23 24 25 26

27

28

29 30 31 32 33 34 35 36 37 38 39 40 41 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

42

3

4

5

6

7

8

9

54

LU-02589

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Oil Pressure System LUBRICATION

B: INSPECTION 1

2

3

Step Check CHECK COMBINATION METER. Does the warning light illumi1) Turn the ignition switch to ON. (engine OFF) nate? 2) Check the warning light of combination meter.

Yes Go to step 2.

CHECK HARNESS CONNECTOR BETWEEN Is the voltage 10 V or more? COMBINATION METER AND OIL PRESSURE SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from oil pressure switch. 3) Turn the ignition switch to ON. 4) Measure the voltage of harness between oil pressure switch connector and chassis ground. Connector & terminal (E11) No. 1 (+) — Chassis ground (–): CHECK COMBINATION METER. Is the resistance less than 10 1) Turn the ignition switch to OFF. Ω? 2) Remove the combination meter. 3) Measure the resistance of combination meter. Terminals (i10) No. 8 — (i10) No. 19:

Replace the oil pressure switch.

LU(H6DO)-8

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between combination meter and oil pressure switch • Poor contact of combination meter connector • Poor contact of oil pressure switch connector • Poor contact of coupling connector

No Repair or replace the combination meter. Go to step 3.

Repair or replace the combination meter.

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Engine Oil LUBRICATION

3. Engine Oil

B: REPLACEMENT

A: INSPECTION

CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Open the engine oil filler cap for quick draining of engine oil. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain engine oil by loosening the engine oil drain plug.

CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Park the vehicle on a level surface. 2) Remove the oil level gauge and wipe away the oil. 3) Reinsert the oil level gauge all the way. Be sure that the oil level gauge is correctly inserted and properly orientated. 4) Pull out the oil level gauge again, and check the oil level. If the engine oil level is below “L” line, make sure that there is no oil leakage from the engine, then add oil to raise the level up to the “F” line. 5) Start the engine to circulate the oil in engine room. 6) After turning off the engine, wait a few minutes for the oil to return to the oil pan before checking the level. NOTE: • Just after driving or while the engine is warm, engine oil level may be exceeding the “F” line. This is caused by thermal expansion of engine oil. • To prevent overfilling of engine oil, do not add oil above “F” line when the engine is cold. • As the oil level gauge is used for daily inspection, standard of “F” line and “L” line of the oil level gauge is set for the condition that engine is cold. (A)

(B)

(C) (E) (D)

LU-02555

(A) (B) (C) (D) (E)

Oil level gauge Engine oil filler cap “F” line “L” line Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)

NOTE: Prepare the container for draining of engine oil.

LU-02556

5) Tighten the engine oil drain plug after draining engine oil. NOTE: Use a new drain plug gasket.

Tightening torque: 44 N·m (4.5 kgf-m, 32.5 ft-lb) 6) Install the under cover. 7) Lower the vehicle. 8) Using engine oil of proper quality and viscosity, fill engine oil through the oil filler duct to the “F” line on level gauge. Make sure that the vehicle is parked on a level surface when checking oil level. Recommended oil: Refer to “SPECIFICATION” for recommended oil. Engine oil capacity: Refer to “SPECIFICATION” for engine oil capacity. 9) Close the engine oil filler cap. 10) Start the engine to circulate the oil in engine room.

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Engine Oil LUBRICATION

11) After the engine stops, recheck the oil level. If necessary, add engine oil up to the “F” line on level gauge. (A)

(B)

(C) (E) (D)

LU-02555

(A) (B) (C) (D) (E)

Oil level gauge Engine oil filler cap “F” line “L” line Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)

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Oil Pan LUBRICATION

4. Oil Pan

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

A: REMOVAL NOTE: Before removing the oil pan upper, remove the engine from vehicle. 1) Lift up the vehicle. 2) Remove the under cover. 3) Drain the engine oil. 4) Insert an oil pan cutter blade into the gap between oil pan upper and oil pan lower, and remove the oil pan. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter. 5) Remove the oil pan lower.

(8)

(7) (6)

(9)

(5)

(10)

(4)

(11)

(3)

(12) (2)

(1)

(13)

LU-02558

3) Install the under cover. 4) Lower the vehicle. 5) Refill the engine oil. 6) Check the engine oil level.

C: INSPECTION Check that the oil pan upper and oil pan lower have no deformation, cracks or other damages.

LU-02557

B: INSTALLATION 1) Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan lower. NOTE: Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 5.0±1.0 mm (0.197±0.039 in)

LU-02377

2) Tighten the oil pan lower installing bolts in the numerical order as shown in the figure.

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Oil Pump LUBRICATION

5. Oil Pump

14) Remove the stiffener and the oil pump.

A: REMOVAL

(A)

1) Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. (1) Lift up (A) in two positions at the rear. (2) Moving (B) in two positions at the front toward the vehicle, lift them up.

(A)

(B)

(A) (C)

(B)

(B) ME-04447

2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Remove the under cover. 5) Drain the engine oil. 6) Drain engine coolant. 7) Lower the vehicle. 8) Remove the radiator. 9) Remove the V-belts. 10) Remove the crank pulley. 11) Remove the chain cover. 12) Remove the timing chain. 13) Remove the oil pan lower.

LU-02564

(A) Stiffener (B) Oil pan upper (C) Oil pump

15) Remove the strainer from the oil pump. 16) Remove the O-ring from oil pan upper.

LU-02380

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Oil Pump LUBRICATION

B: INSTALLATION 1) Apply engine oil to the O-ring and attach it to the oil pan upper.

Tightening torque: T1: 13 N·m (1.3 kgf-m, 9.6 ft-lb) T2: 24 N·m (2.4 kgf-m, 17.7 ft-lb)

NOTE: Use new O-rings.

T2

(A)

(B)

(C)

T1 LU-02565

(A) Stiffener (B) Oil pan upper (C) Oil pump

LU-02380

2) Apply liquid gasket to the mating surfaces of strainer.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent Liquid gasket applying diameter: 2.0±1.0 mm (0.079±0.039 in) NOTE: • Install within 5 min. after applying liquid gasket. • After installing the strainer, remove any liquid gasket that is squeezed out.

LU-02588

3) Install the strainer to the oil pump.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb) 4) Install the stiffener and the oil pump.

5) Install the oil pan lower. 6) Install the timing chain. 7) Install the chain cover. 8) Install the crank pulley. 9) Install the V-belts. 10) Install the radiator. 11) Lift up the vehicle. 12) Install the under cover. 13) Lower the vehicle. 14) Fill the ATF. 15) Refill the engine oil. 16) Check the engine oil level.

C: INSPECTION • Visually check the oil pump for breakage. • Visually check the strainer portion for clogging.

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Oil Pressure Switch LUBRICATION

6. Oil Pressure Switch

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain the engine oil. 5) Disconnect the terminal from oil pressure switch.

LU-02560

3) Connect the terminal of the oil pressure switch.

LU-02559

6) Remove the oil pressure switch. LU-02559

4) Install the under cover. 5) Refill the engine oil. 6) Check the engine oil level. LU-02560

B: INSTALLATION 1) Apply liquid gasket to the oil pressure switch threads.

C: INSPECTION 1) Check that the oil pressure switch does not have deformation, cracks or damage. 2) Check the oil pressure switch installation portion for oil leakage and oil seepage.

Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent

LU-00129

2) Install the oil pressure switch.

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Engine Oil Filter LUBRICATION

7. Engine Oil Filter A: REMOVAL CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Lift up the vehicle. 2) Drain the engine oil. 3) Remove the under cover. 4) Remove the engine oil filter using the ST. ST 18332AA020 OIL FILTER WRENCH

LU-02561

B: INSTALLATION CAUTION: Do not tighten excessively, or oil may leak. 1) Clean the engine oil filter installation surface of the oil cooler. 2) Obtain a new engine oil filter and apply a thin coat of engine oil to the seal rubber. 3) Install the engine oil filter turning it by hand, being careful not to damage the seal rubber. 4) Tighten more (approx. 3/4 turn) after the seal rubber contacts the oil cooler. When using a torque wrench, tighten to 14 N·m (1.4 kgf-m, 10.3 ft-lb). 5) Install the under cover. 6) Lower the vehicle. 7) Refill the engine oil. 8) Check the engine oil level.

C: INSPECTION 1) After installing the engine oil filter, run the engine and make sure that no oil is leaking around seal rubber. NOTE: The filter element and filter case are permanently jointed; therefore, interior cleaning is not necessary. 2) Check the engine oil level.

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Oil Cooler LUBRICATION

8. Oil Cooler

NOTE: Use new O-rings.

A: REMOVAL CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Lift up the vehicle. 2) Remove the under cover. 3) Drain engine coolant. 4) Drain the engine oil. 5) Remove the bolts which hold the engine oil cooler water pipe to chain cover and disconnect the water hose from oil cooler.

(B)

(C)

(D)

(A)

(A) (B) (C) (D)

LU-02384

Oil cooler connector Oil cooler O-ring Oil pan upper

2) Attach the engine oil filter. 3) Attach the bolts which hold the engine oil cooler water pipe to chain cover and connect the water hose to oil cooler.

Tightening torque: T: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

LU-02562

T

6) Remove the engine oil filter using the ST. ST 18332AA020 OIL FILTER WRENCH 7) Remove the oil cooler connector and remove the oil cooler.

LU-02563 (B)

(C)

(D)

(A)

(A) (B) (C) (D)

LU-02384

Oil cooler connector Oil cooler O-ring Oil pan upper

4) Install the under cover. 5) Lower the vehicle. 6) Fill the ATF. 7) Refill the engine oil. 8) Check the engine oil level.

C: INSPECTION

B: INSTALLATION 1) Tighten the oil cooler connector to install the oil cooler to the oil pan upper.

1) Check that coolant passages are not clogged using an compressed air. 2) Check that the oil pan upper and O-ring installing surface of oil filter are not damaged.

Tightening torque: 54 N·m (5.5 kgf-m, 39.8 ft-lb)

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Oil Level Switch LUBRICATION

9. Oil Level Switch

7) Remove the oil level switch from the oil pan upper.

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the under cover. 4) Drain the engine oil. 5) Disconnect the connector of oil level switch from the engine harness.

LU-02593

8) Remove the oil level switch.

B: INSTALLATION 1) Route the oil level switch harness as shown in the figure.

LU-02590

6) Remove the clips which hold the front camshaft cap (LH) and cylinder head (LH).

(A)

LU-02591

LU-02594

(A) Route the oil level switch harness through inside of oil pan upper bolt.

2) Attach the oil level switch to the oil pan upper. LU-02592

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Oil Level Switch LUBRICATION

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

LU-02593

3) Attach the clips which hold the front camshaft cap (LH) and cylinder head (LH).

LU-02591

LU-02592

4) Connect the connector of oil level switch to the engine harness.

LU-02590

5) Install the under cover. 6) Lower the vehicle. 7) Refill the engine oil. 8) Check the engine oil level.

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Oil Level Switch LUBRICATION

C: WIRING DIAGRAM

TO POWER SUPPLY CIRCUIT FB-30 F/B FUSE NO. 5 (IG)

FB-17 F/B FUSE NO. 7 (B)

*1 *2

J/C

*

*

2

2

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 7, 8, 9, 10, 11 AND 12

20

19

i82

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 3, 4, 5 AND 6

I/F

LOW ENGINE OIL WARNING LIGHT

COMBINATION METER

POWER SUPPLY CIRCUIT

i10

DRIVE CIRCUIT

MICRO COMPUTER

32

33

39

17

28

*1

CAN TRANSCEIVER & RECEIVER

J/C i 98

26

*1

B 1 3 6 ECM

B 21 16

OIL LEVEL SWITCH

E2

E 130

B21 i82 i98 1 2 3 4 5 6 7 8 9 10 11 12

B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

i10 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

LU-02654

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Oil Level Switch LUBRICATION

D: INSPECTION 1. INSPECTION WHILE OIL LEVEL SWITCH WARNING LIGHT IS ON 1

Step CHECK ENGINE OIL LEVEL.

Check Is engine oil level normal?

2

CHECK LAN SYSTEM.

Has a DTC of the LAN system Perform the diagnosis according to been input? DTC.

LU(H6DO)-20

Yes Go to step 2.

No Replace engine oil or refill, and check again while the oil level is normal condition. To turn off the oil level warning light, install the spare fuse at the delivery (test) mode fuse in the main fuse box. Then turn the ignition switch to ON (engine off) again, to confirm the warning light turns off. Remove the spare fuse installed to finish this step. NOTE: The engine oil level switch is normal, if the low engine oil level warning light turns off with the delivery (test) mode fuse installed. Go to step 3.

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Oil Level Switch LUBRICATION

3

4

5

Step Check CHECK OIL LEVEL SWITCH CIRCUIT. Is the “Oil level switch” signal 1) Turn the ignition switch to ON (engine OFF). displayed in Subaru Select 2) Read the current data for engine in the Sub- Monitor HIGH? aru Select Monitor to confirm the item for “Oil level switch”.

CHECK COMBINATION METER. Perform the self-diagnosis of combination meter to check if there are any faults in the combination meter. CHECK SECURE CONNECTION OF CONNECTOR BETWEEN ENGINE HARNESS AND OIL LEVEL SWITCH.

Is the combination meter normal?

Is there any insecure connection?

LU(H6DO)-21

Yes No To turn off the oil Go to step 4. level warning light, install the spare fuse at the delivery (test) mode fuse in the main fuse box. Then turn the ignition switch to ON (engine off) again, to confirm the warning light turns off. Remove the spare fuse installed to finish this step. NOTE: The engine oil level switch is normal, if the low engine oil level warning light turns off with the delivery (test) mode fuse installed. Go to step 5. Replace the combination meter.

Remedy the con- Go to step 6. nection condition. Then, to turn off the oil level warning light, install the spare fuse at the delivery (test) mode fuse in the main fuse box. Then turn the ignition switch to ON (engine off) again, to confirm the warning light turns off. Remove the spare fuse installed to finish this step. NOTE: The engine oil level switch is normal, if the low engine oil level warning light turns off with the delivery (test) mode fuse installed.

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Oil Level Switch LUBRICATION

6

7

8

Step CHECK OIL LEVEL SWITCH. 1) Deliberately short circuits by connecting the engine harness connector terminal and chassis ground. 2) Turn the ignition switch to ON (engine OFF). 3) Read the current data for engine in the Subaru Select Monitor to confirm the item for “Oil level switch”. Connector & terminal (E130) No. 1 — Chassis ground: CHECK SECURE CONNECTION OF CONNECTOR BETWEEN BULKHEAD HARNESS AND ENGINE HARNESS.

Check Is the “Oil level switch” signal displayed in Subaru Select Monitor HIGH?

Is there any insecure connection?

Yes No Replace the oil Go to step 7. level switch.

Remedy the con- Go to step 8. nection condition. Then, to turn off the oil level warning light, install the spare fuse at the delivery (test) mode fuse in the main fuse box. Then turn the ignition switch to ON (engine off) again, to confirm the warning light turns off. Remove the spare fuse installed to finish this step. NOTE: The engine oil level switch is normal, if the low engine oil level warning light turns off with the delivery (test) mode fuse installed. CHECK ENGINE HARNESS. Is the resistance less than 1 Ω? Go to step 9. Repair or replace 1) Disconnect the oil level switch side connecthe open circuit of tor of the engine harness. engine harness. 2) Disconnect the bulkhead harness side connector of the engine harness. 3) Measure the resistance between connector terminals. Connector & terminal (E2) No. 16 — (E130) No. 1:

LU(H6DO)-22

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Oil Level Switch LUBRICATION

9

10

Step Check CHECK SECURE CONNECTION OF CONIs there any insecure connecNECTOR BETWEEN ENGINE CONTROL tion? MODULE (ECM) AND BULKHEAD HARNESS. Remove the glove box lid assembly.

Yes Remedy the connection condition. Then, to turn off the oil level warning light, install the spare fuse at the delivery (test) mode fuse in the main fuse box. Then turn the ignition switch to ON (engine off) again, to confirm the warning light turns off. Remove the spare fuse installed to finish this step. NOTE: The engine oil level switch is normal, if the low engine oil level warning light turns off with the delivery (test) mode fuse installed. Is the resistance less than 1 Ω? Replace the Engine Control Module (ECM).

No Go to step 10.

CHECK BULKHEAD HARNESS. 1) Remove the glove box lid assembly. 2) Disconnect the engine control module (ECM) side connector of the bulkhead harness. 3) Disconnect the engine harness connectors of the bulkhead harness. 4) Measure the resistance between connector terminals. Connector & terminal (B136) No. 26 — (B21) No. 16:

Repair or replace the open circuit of bulkhead harness.

2. OTHER INSPECTIONS 1) Check that the oil level switch does not have deformation, cracks, or damage. 2) Check the oil level switch installation part for oil leakage and oil seepage.

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Engine Lubrication System Trouble in General LUBRICATION

10.Engine Lubrication System Trouble in General A: INSPECTION Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists. Trouble

Warning light remains ON.

Warning light does not illuminate.

Warning light flickers momentarily.

Possible cause a. Oil pressure switch failure Cracked diaphragm or oil leakage within switch Broken spring or seized contacts b. Low oil pressure Clogging of oil filter Malfunction of oil by-pass valve in oil filter Malfunction of oil relief valve in oil pump Clogged oil passage Excessive tip clearance and side clearance of oil pump rotor Clogged oil strainer or broken pipe c. No oil pressure Insufficient engine oil (degradation, etc.) Broken pipe of oil strainer Stuck oil pump rotor a. Defective combination meter b. Poor contact of switch contact points c. Disconnection of wiring a. Defective terminal contact b. Defective wiring harness c. Oil pressure switch failure Cracked diaphragm or oil leakage within switch Broken spring or seized contacts d. Low oil pressure Clogging of oil filter

Corrective action Replace. Replace. Replace. Replace. Replace. Clean. Replace. Clean or replace. Replace. Replace. Replace. Replace. Replace. Repair. Repair. Repair. Replace. Replace. Replace.

Malfunction of oil by-pass valve in oil filter Malfunction of oil relief valve in oil pump Clogged oil passage Excessive tip clearance and side clearance of oil pump

Replace. Replace. Clean.

Clogged oil strainer or broken pipe

Clean or replace.

rotor

LU(H6DO)-24

Replace.

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SPEED CONTROL SYSTEMS

SP(H6DO) 1.

Page General Description ...................................................................................2

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General Description SPEED CONTROL SYSTEMS

1. General Description A: SPECIFICATION Specifications for the 3.6 L DOHC non-turbo model are the same as the 2.5 L SOHC non-turbo model.

SP(H6DO)-2

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IGNITION

IG(H6DO) 1. 2. 3.

Page General Description ...................................................................................2 Spark Plug ..................................................................................................4 Ignition Coil ................................................................................................7

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General Description IGNITION

1. General Description A: SPECIFICATION Item Type Ignition system Manufacturer Manufacturer and type Thread size (diameter, pitch, length) mm Spark plug gap mm (in) Standard

Ignition coil

Spark plug

SPECIFICATION FK0368 Independent ignition coil Diamond Electric NGK: SILFR6C11 14,1.25,26.5 1.0 — 1.1 (0.039 — 0.043)

Electrode

Iridium

B: COMPONENT

T1

(1) (2)

T2

(1) (2) T2

T1

IG-00052

(1) (2)

Tightening torque:N·m (kgf-m, ft-lb) T1: 16 (1.6, 11.8) T2: 21 (2.1, 15.5)

Spark plug Ignition coil

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General Description IGNITION

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.

IG(H6DO)-3

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Spark Plug IGNITION

2. Spark Plug

7) Remove the spark plug with a spark plug socket.

A: REMOVAL Spark plug:

1. RH SIDE 1) Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. (1) Lift up (A) in two positions at the rear. (2) Moving (B) in two positions at the front toward the vehicle, lift them up.

IG-02005

(B)

(B)

(C)

(D)

(A)

(A)

(A) IG-02011

(A) (B) (C) (D)

(B)

(B)

ME-04447

2) Disconnect the ground cable from battery. 3) Remove the air cleaner case. 4) Remove the bracket (A). 5) Disconnect the connector (B) from ignition coil. (A)

Ratchet handle Extension bar Universal joint Spark plug socket

2. LH SIDE 1) Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. (1) Lift up (A) in two positions at the rear. (2) Moving (B) in two positions at the front toward the vehicle, lift them up.

(B)

(A)

IG-02076

(A)

6) Remove the ignition coil. NOTE: Turn the #5 ignition coil to remove it.

(B)

(B) ME-04447

2) Remove the battery and battery carrier. 3) Remove the bracket (A).

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Spark Plug IGNITION

4) Disconnect the connector (B) from ignition coil.

2. LH SIDE Install in the reverse order of removal.

(A)

Tightening torque: Spark plug 21 N·m (2.1 kgf-m, 15.5 ft-lb) Ignition coil 16 N·m (1.6 kgf-m, 11.8 ft-lb) Bracket (A) 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

(B)

C: INSPECTION

IG-02077

5) Remove the ignition coil. NOTE: Turn the #6 ignition coil to remove it. 6) Remove the spark plug with a spark plug socket.

1) Check the spark plug for abnormalities. If defective, replace the spark plug. (C)

(A) (B)

(A) Terminal damage (B) Crack or damage in insulator (C) Damaged gasket

IG-02007

(C)

IG-02094

2) Check the spark plug electrode and condition of the insulator. If abnormal, check and repair the cause and replace the spark plug. (1) Normal: Brown to grayish-tan deposits and slight electrode wear indicate correct spark plug heat range.

(B)

(A)

IG-02101

(A) Ratchet handle (B) Extension bar (C) Spark plug socket

B: INSTALLATION 1. RH SIDE Install in the reverse order of removal.

IG-00011

Tightening torque: Spark plug 21 N·m (2.1 kgf-m, 15.5 ft-lb) Ignition coil 16 N·m (1.6 kgf-m, 11.8 ft-lb) Bracket (A) 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

IG(H6DO)-5

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Spark Plug IGNITION

(2) Carbon fouled: Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in the city, weak ignition, too rich fuel mixture, etc.

• Do not use a metal brush as it may damage the electrode area.

Spark plug gap L: Standard 1.0 — 1.1 mm (0.039 — 0.043 in)

L

IG-00012

(3) Oil fouled: Wet black deposits show oil entrance into combustion chamber through worn piston rings or increased clearance between valve guides and valve stems.

IG-00013

(4) Overheating: White or light gray insulator with black or brown spots and bluish burnt electrodes indicate engine overheating, wrong selection of fuel, or loose spark plugs.

IG-00014

3) Using a nylon brush, etc., clean and remove the carbon or oxide deposits from the spark plug. If deposits are too stubborn, replace the spark plugs. After cleaning the spark plugs, check the spark plug gap “L” using a gap gauge. If it is not within the standard, replace the spark plug. NOTE: • Never use a plug cleaner.

IG(H6DO)-6

IG-02095

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Ignition Coil IGNITION

3. Ignition Coil A: REMOVAL Direct ignition type has been adopted. Refer to “Spark Plug” for removal procedure.

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

C: INSPECTION For inspection procedure, refer to “Diagnostics for Engine Starting Failure”.

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Ignition Coil IGNITION

IG(H6DO)-8

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STARTING/CHARGING SYSTEMS

SC(H6DO) 1.

Page General Description ...................................................................................2

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General Description STARTING/CHARGING SYSTEMS

1. General Description A: SPECIFICATION Specifications for the 3.6 L DOHC non-turbo model are included in the SC (H4SO) section.

SC(H6DO)-2

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ENGINE (DIAGNOSTICS)

EN(H6DO)(diag) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Page Basic Diagnostic Procedure .......................................................................2 Check List for Interview ..............................................................................4 General Description ...................................................................................6 Electrical Component Location ..................................................................9 Engine Control Module (ECM) I/O Signal ................................................18 Engine Condition Data .............................................................................27 Data Link Connector ................................................................................28 General Scan Tool ...................................................................................29 Subaru Select Monitor ..............................................................................35 Read Diagnostic Trouble Code (DTC) .....................................................44 Inspection Mode .......................................................................................45 Drive Cycle ...............................................................................................50 Clear Memory Mode .................................................................................57 System Operation Check Mode ...............................................................58 Malfunction Indicator Light .......................................................................59 Diagnostics for Engine Starting Failure ....................................................69 List of Diagnostic Trouble Code (DTC) ....................................................82 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................91 General Diagnostic Table .......................................................................349

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Basic Diagnostic Procedure ENGINE (DIAGNOSTICS)

1. Basic Diagnostic Procedure A: PROCEDURE 1. ENGINE 1

Step Check CHECK ENGINE START FAILURE. Does the engine start? 1) Ask the customer when and how the trouble occurred using the interview check list. 2) Start the engine.

2

CHECK ILLUMINATION OF MALFUNCTION Does the malfunction indicator light illuminate? INDICATOR LIGHT.

3

CHECK COMMUNICATION STATUS. Does Subaru select monitor or 1) Turn the ignition switch to OFF. general scan tool communicate 2) Connect the Subaru Select Monitor or gen- with vehicle normally? eral scan tool to data link connector. 3) Turn the ignition switch to ON, and run the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed procedures, refer to “Subaru Select Monitor”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

4

CHECK DTC. Is DTC displayed on Subaru Read DTC using Subaru Select Monitor or gen- Select Monitor or general scan eral scan tool. tool? NOTE: • Subaru Select Monitor Refer to “Read Diagnostic Trouble Code” for detailed operation procedure. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H6DO)(diag)-2

Yes Go to step 2.

No Inspection using “Diagnostics for Engine Start Failure”. Go to step 3. Inspection using “General Diagnostic Table”. Go to step 4. Inspection using LAN system “Diagnostic Procedure with Diagnostic Trouble Code (DTC)”. Record the DTC. Repair the related Repair the trouble parts. cause. function indicator Go to step 5. light illuminates, perform the diagnosis of malfunction indicator light circuit or combination meter.

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Basic Diagnostic Procedure ENGINE (DIAGNOSTICS)

5

6

Step CHECK FREEZE FRAME DATA. Check the freeze frame data using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed procedures, refer to “Subaru Select Monitor”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. PERFORM DIAGNOSIS. 1) Perform the Clear Memory Mode. 2) Perform the Inspection Mode or drive cycle.

Check Yes No Is freeze frame data displayed Record the freeze Go to step 6. on Subaru Select Monitor or frame data. Repair general scan tool? the cause of fault, and go to the next step. Go to step 6.

Inspect using Is DTC displayed on Subaru Finish the diagnoSelect Monitor or general scan “Diagnostic Proce- sis. dure with Diagnostool? tic Trouble Code (DTC)”.

EN(H6DO)(diag)-3

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Check List for Interview ENGINE (DIAGNOSTICS)

2. Check List for Interview A: CHECK 1. CHECK LIST NO. 1 Check the following item when problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer’s name Date of purchase Date of repair V.I.N. Weather

Engine No. Fuel brand

Fine Cloudy Rainy Snowy Various/Others:

Ambient air temperature

Place

Engine temperature

Engine speed Vehicle speed Driving conditions

Headlight Blower A/C compressor Radiator fan Front wiper Rear wiper

km miles

Odometer reading

°C (

°F)

Hot Warm Cool Cold Highway Suburbs Inner city Uphill Downhill Rough road Others: Cold Warming-up After warming-up Any temperature Others: rpm km/h (MPH) Not affected At starting While idling At racing While accelerating While cruising While decelerating While turning (RH/LH) ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF

Rear defogger Audio CD/Cassette Car phone Wireless device

EN(H6DO)(diag)-4

ON/ ON/ ON/ ON/ ON/

OFF OFF OFF OFF OFF

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Check List for Interview ENGINE (DIAGNOSTICS)

2. CHECK LIST NO. 2 Check the following item about the vehicle’s state when malfunction indicator light turns on. NOTE: Use copies of this page for interviewing customers. a) Other warning lights or indicators illuminate. Yes / No Low fuel warning light Charge indicator light Engine coolant temperature warning light Oil pressure warning light ATF temperature warning light or SPORT indicator light Driver’s control center differential indicator light ABS warning light VDC warning light Cruise indicator light SI-CRUISE warning light Immobilizer indicator light STEERING warning light Glow indicator light Sedimentor warning light Electronic parking brake warning light Others: b) Fuel level • Lack of fuel: Yes / No • Indicator position of fuel gauge: • Experienced running out of fuel: Yes / No c) Intentional connecting or disconnecting of harness connectors or spark plug cords: Yes / • What: d) Intentional connecting or disconnecting of hoses: Yes / No • What: e) Installing of other parts except genuine parts: Yes / No • What: • Where: f) Occurrence of noise: Yes / No • From where: • What kind: g) Occurrence of smell: Yes / No • From where: • What kind: h) Intrusion of water into engine compartment or passenger compartment: Yes / No i) Troubles occurred Engine does not start. Engine stalls during idling. Engine stalls while driving. Engine speed decreases. Engine speed does not decrease. Rough idling Poor acceleration Back fire After fire Does not shift. Excessive shift shock

EN(H6DO)(diag)-5

No

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General Description ENGINE (DIAGNOSTICS)

3. General Description

7) Use ECM mounting stud bolts at the body side grounding point when measuring voltage and resistance inside the passenger compartment.

A: CAUTION 1) Airbag system wiring harness is routed near the ECM, main relay and fuel pump relay. CAUTION: • Do not use electrical test equipment on the airbag system circuit. • Be careful not to damage the airbag system wiring harness when servicing the ECM, TCM, main relay and fuel pump relay. 2) Never connect the battery in reverse polarity. Doing so will damage the ECM instantly, and other parts will also be damaged. 3) Do not disconnect the battery terminals while the engine is running. A large counter electromotive force will be generated in the generator, and this voltage may damage electronic parts such as ECM etc. 4) Before disconnecting the connectors of each sensor and ECM, be sure to turn the ignition switch to OFF. Perform the Clear Memory Mode after connecting the connectors. 5) When measuring the voltage or resistance of individual sensor or all electrical control modules, use a tapered pin with a diameter of less than 0.6 mm (0.024 in). Do not insert the pin 4 mm (0.16 in) or more into the part. CAUTION: When replacing the ECM, be careful not to use the wrong spec. ECM to avoid any damage on the fuel injection system. NOTE: When replacing the ECM of the models with Immobilizer, immobilizer system must be registered. To do so, all ignition keys and ID cards need to be prepared. Refer to the “PC application help for Subaru Select Monitor”. 6) Take care not to allow water to get into the connectors when servicing or washing the vehicle in rainy weather. Avoid exposure to water even if the connectors are waterproof.

(A)

EN-07713

(A) Stud bolt

8) Use the engine ground terminal or engine assembly as the grounding point to chassis when measuring the voltage and resistance in engine compartment.

EN-07529

9) Every MFI-related part is a precision part. Do not drop them. 10) Observe the following cautions when installing a radio in vehicle. CAUTION: • The antenna must be kept as far apart as possible from control module. (ECM is installed at the back of the glove box.) • The antenna feeder must be placed as far apart as possible from the ECM and engine control system harness. • Carefully adjust the antenna for correct matching. • When mounting a large power type radio, pay special attention to the three items mentioned above. • Incorrect installation of the radio may affect the operation of ECM. 11) When disconnecting the fuel hose, release the fuel pressure.

EN(H6DO)(diag)-6

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General Description ENGINE (DIAGNOSTICS)

12) For the model with ABS, the ABS warning light may illuminate when performing driving test with jacked-up or lifted-up condition, but this is not a system malfunction. The reason for this is the speed difference between the front and rear wheels. When engine control system diagnosis is finished, perform the VDC memory clearance procedure of self-diagnosis function.

B: INSPECTION Before performing diagnostics, check the following item which might affect engine problems.

1. BATTERY 1) Measure the battery voltage and specific gravity of the electrolyte.

• The OBD system stores freeze frame engine condition data (engine load, engine coolant temperature, fuel trim, engine speed and vehicle speed, etc.) into on-board computer when it detects a malfunction. • Freeze frame engine condition data are stored until the DTCs are cleared. However when such malfunctions as fuel trim fault and misfire are detected with the freeze frame engine condition data stored, they are rewritten into those related to the fuel trim fault and misfire. • When the malfunction does not occur again for three consecutive driving cycles, malfunction indicator light is turned off, but DTC remains at onboard computer. • When performing diagnosis, connect the Subaru Select Monitor or general scan tool to the vehicle.

Standard voltage: 12 V Specific gravity: 1.260 or more 2) Check the condition of the main and other fuses, and harnesses and connectors. Also check for proper grounding.

2. ENGINE GROUND Make sure that the engine ground terminal is properly connected to the engine.

EN-07529

C: NOTE • The on-board diagnostic (OBD) system detects and indicates a fault in various inputs and outputs of the complex electronic control. Malfunction indicator light in the combination meter indicates occurrence of a fault or trouble. • Further, against such a failure of sensors as may disable the drive, the fail-safe function is provided to ensure the minimal driveability. • The OBD system incorporated with the vehicles within this type of engine complies with OBD-II regulations. The OBD system monitors the components and the system malfunction listed in “Engine Section” which affects on emissions. • When the system decides that a malfunction occurs, malfunction indicator light illuminates. At the same time of the malfunction indicator light illumination or blinking, a DTC and a freeze frame engine conditions are stored into on-board computer.

EN(H6DO)(diag)-7

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General Description ENGINE (DIAGNOSTICS)

D: PREPARATION TOOL ILLUSTRATION

TOOL NUMBER 1B022XU0

DESCRIPTION

REMARKS

SUBARU SELECT MONITOR III KIT

Used for troubleshooting the electrical system.

CRANKSHAFT SOCKET

Used for rotating crankshaft.

ST1B022XU0

18252AA000

ST18252AA000

EN(H6DO)(diag)-8

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Electrical Component Location ENGINE (DIAGNOSTICS)

4. Electrical Component Location A: LOCATION 1. CONTROL MODULE (1)

(3)

(4)

(2) EN-07827

(1) (2)

Engine control module (ECM) Malfunction indicator light

(3)

Delivery (test) mode fuse

(4)

Data link connector

(1) CHECK ENGINE

CHECK ENGINE

(2)

EN-07715

EN-07716

(3)

(4) EN-07528

EN(H6DO)(diag)-9

EN-07717

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Electrical Component Location ENGINE (DIAGNOSTICS)

2. SENSOR

(8)

(1)

(9)

(3)

(2)

(4)

(5)

(8)

(5)

(6)

(7)

(9) EN-07828

(1) (2) (3)

Mass air flow and intake air temperature sensor Manifold absolute pressure sensor Electronic throttle control

(4)

Crankshaft position sensor

(7)

Oil temperature sensor

(5) (6)

Knock sensor Engine coolant temperature sensor

(8) (9)

Intake camshaft position sensor Exhaust camshaft position sensor

EN(H6DO)(diag)-10

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Electrical Component Location ENGINE (DIAGNOSTICS)

(2) (1)

EN-07531

EN-07532

(4)

(3)

(5)

EN-07829

EN-07830

(8)

(6)

(7) EN-07831

(9)

EN-07833

EN(H6DO)(diag)-11

EN-07832

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2015年12月24日 木曜日 午後5時18分

Electrical Component Location ENGINE (DIAGNOSTICS)

(1)

(2)

(3)

(4)

(8)

(7)

(6) (5)

EN-07539

(1) (2) (3)

Front oxygen (A/F) sensor RH Front catalytic converter RH Rear oxygen sensor RH

(4) (5) (6)

Rear catalytic converter RH Front oxygen (A/F) sensor LH Front catalytic converter LH

EN(H6DO)(diag)-12

(7) (8)

Rear oxygen sensor LH Rear catalytic converter LH

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Electrical Component Location ENGINE (DIAGNOSTICS)

(1) (2)

(3)

(4)

(1) (2)

Fuel level sensor Fuel temperature sensor

(3)

Fuel tank pressure sensor

(4)

EN-07834

Fuel sub level sensor

(3)

(1)

(2) EN-07718

(4)

EN-07720

EN(H6DO)(diag)-13

EN-07719

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Electrical Component Location ENGINE (DIAGNOSTICS)

3. SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS (1)

(5)

(6)

(4)

(2)

(3)

(3)

(5)

(4)

(6) EN-07835

(1)

Purge control solenoid valve

(3)

Intake oil flow control solenoid valve

(5)

Fuel injector

(2)

EGR valve

(4)

Exhaust oil flow control solenoid valve

(6)

Ignition coil

EN(H6DO)(diag)-14

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Electrical Component Location ENGINE (DIAGNOSTICS)

(1) (2)

EN-07836

EN-07837

(3)

(4)

EN-07543

EN-07544

(6)

(5) EN-07545

EN(H6DO)(diag)-15

EN-07546

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Electrical Component Location ENGINE (DIAGNOSTICS)

(3) (4) (5) (6) (7)

(8)

(1)

(9)

(10)

(2)

(12)

(11)

(13) EN-07838

(1) (2) (3) (4) (5)

Starter Fuel pump Main relay IG relay A/F, oxygen sensor relay

(6) (7) (8) (9)

Electronic throttle control relay Fuel pump relay Main fan relay Starter relay

EN(H6DO)(diag)-16

(10) (11) (12) (13)

Inhibitor relay Canister Drain valve Drain filter

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Electrical Component Location ENGINE (DIAGNOSTICS)

(2) (1)

EN-07519

EN-07752

(3) (4) (5) (6)

(8)

(7)

EN-07721

EN-07525

(13)

(12)

(10) (11) (9) EN-07728

EN(H6DO)(diag)-17

EN-07729

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

5. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION

TO A:

B134

7 6 5 4 3 17 16 15 14 13 12 11 27 26 25 24 23 22 21 34 33 32 31

TO B: 2 1 10 9 8 20 19 18 30 29 28

B135

TO C:

7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 35 34 33 32 31 30 29 28

B136

TO D:

6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 27 26 25 24 23 22 21 20 19 18 17 30 29 28 35 34 33 32 31

B137

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26

EN-05288

Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) 0 –7 — +7 0 0 0 0

Connector No.

Terminal No.

B137 B137 B137

17 25 31

B137

16

0 or 5

0 or 5

Waveform

Intake camshaft position sensor (RH)

B137

24

0 or 5

0 or 5

Waveform

Exhaust camshaft position sensor (LH)

B137

29

0 or 5

0 or 5

Waveform

Exhaust camshaft position sensor (RH)

B137

23

0 or 5

0 or 5

Waveform

Camshaft position sensor ground

B137

30

0

0



Main

B134

18

0.64 — 0.94 Fully open: Approx. 4.04

0.64 — 0.72 (After engine is warmed up.)

Fully closed: Approx. 0.6 Fully open: Approx. 4.04

Sub

B134

28

1.51 — 1.76 Fully open: Approx. 4.232

1.51 — 1.58 (After engine is warmed up.)

Fully closed: Approx. 1.48 Fully open: Approx. 4.232

B134

2

Duty waveform

Duty waveform

Drive frequency: 500 Hz

B134

1

Duty waveform

Duty waveform

Drive frequency: 500 Hz

B135

7

10 — 13

12 — 14



B135

17

ON: 0 OFF: 10 — 13

ON: 0 OFF: 12 — 14

When ignition switch is turned to ON: ON

Description Signal (+) Signal (–) Shield Intake camshaft position sensor (LH) Crankshaft position sensor

Electronic throttle control

Electronic throttle control motor (+) Electronic throttle control motor (–) Electronic throttle control motor power supply Electronic throttle control motor relay

EN(H6DO)(diag)-18

Note Waveform — —

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Terminal No.

B135

23

B135

21

5

5



B135

29

0

0



B135

31

Fully closed: 1 Fully opened: 3.7

Fully closed: 1 Fully opened: 3.3



Sub power supply

B135

22

5

5



Ground (sub sensor)

B135

30

0

0



B137

22

1.0 — 1.4

1.0 — 1.4

After engine is warmed up.

B136

16

0

0

Cranking: 8 — 14

ON: 0 OFF: 10 — 13 10 — 13

ON: 0 OFF: 12 — 14 12 — 14

Main sensor signal

Accelerator pedal position sensor

Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) Fully closed: 1 Fully closed: 1 Fully opened: 3.6 Fully opened: 3.3

Connector No.

Description

Main power supply Ground (main sensor) Sub sensor signal

Engine coolant temperature sensor Starter switch Starter relay

B135

26

Ignition switch

B136

30

ON: 0 OFF: 12±0.5

Note —

— — Switch is ON when select lever is in “P” range or “N” range. When fuse is installed: 0 — — —

Neutral position switch

B136

35

Delivery (test) mode fuse Knock sensor 1 Knock sensor 2 Knock sensor shield

B136 B137 B137 B137

34 2 4 8

10 — 13 2.4 2.4 0

12 — 14 2.4 2.4 0

Back-up power supply

B136

2

10 — 13

12 — 14

Ignition switch “OFF”: 10 — 13

Control module power supply

B137 B136 B134

7 1 19

10 — 13 10 — 13 5

12 — 14 12 — 14 5

— — —

B134 B134 B134 B134 B134 B134 B134 B134 B134 B134 B134 B134

21 22 31 32 25 26 10 11 12 13 23 24

B135

11

0 or 5 0 or 5 0 or 5 0 or 5 0 or 5 0 or 5 1 — 14 1 — 14 1 — 14 1 — 14 1 — 14 1 — 14 ON: 0.5 or less OFF: 12 — 14

Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform

Radiator fan control

0 0 0 0 0 0 10 — 13 10 — 13 10 — 13 10 — 13 10 — 13 10 — 13 ON: 0.5 or less OFF: 10 — 13

Radiator fan control power supply

B135

12

ON: 0.5 or less OFF: 10 — 13

ON: 0.5 or less OFF: 12 — 14

Self-shutoff control

B135

13

0

0

Malfunction indicator light

B135

33





Engine speed output

B135

15



0 — 13 or more

Sensor power supply

Ignition control

Fuel injector

#1 #2 #3 #4 #5 #6 #1 #2 #3 #4 #5 #6

EN(H6DO)(diag)-19

— — — Light “ON”: 1 or less Light “OFF”: 10 — 14 Waveform

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

Description Purge control solenoid valve Signal 1 Signal 2 EGR valve Signal 3 Signal 4 Manifold absolute pressure sensor Signal Air flow senShield sor Ground Intake air temperature sensor

Signal (V) Ignition SW ON Engine ON (engine OFF) (idling) ON: 1 or less ON: 1 or less OFF: 10 — 13 OFF: 12 — 14 0 or 10 — 13 0 or 12 — 14 0 or 10 — 13 0 or 12 — 14 0 or 10 — 13 0 or 12 — 14 0 or 10 — 13 0 or 12 — 14

Connector No.

Terminal No.

B137

6

B134 B134 B134 B134

8 9 20 30

B137

20

3.5 — 4.8

1.1 — 1.9



B136 B136 B136

22 10 11

0.74 0 0

0.3 — 4.5 0 0

— — —

B136

31

3.15 — 3.33

3.15 — 3.33

Ambient air temperature

Note — — — — —

Front oxygen (A/F) sensor LH

Signal (+) Signal (–) Shield

B135 B135 B136

8 20 9

2.8 — 3.2 2.4 — 2.7 0

2.8 — 3.2 2.4 — 2.7 0

— — —

Front oxygen (A/F) sensor heater LH

Signal 1

B135

2

12 — 14



Waveform

Signal 2

B135

1

12 — 14



Waveform

Front oxygen (A/F) sensor RH

Signal (+) Signal (–) Shield

B136 B136 B136

19 18 9

2.8 — 3.2 2.4 — 2.7 0

2.8 — 3.2 2.4 — 2.7 0

— — —

B136

6

12 — 14



Waveform

B136

5

12 — 14



Waveform

B135

28

0

0 — 0.9



B136

9

0

0



B135

5

12 — 14



Waveform

B136

20

0

0 — 0.9



B136

9

0

0



B135

6

12 — 14



Waveform

Front oxySignal 1 gen (A/F) sensor Signal 2 heater RH Rear oxySignal gen sensor Shield LH Rear oxygen sensor heater LH signal Rear oxySignal gen sensor Shield RH Rear oxygen sensor heater RH signal Immobilizer communication Fuel pump control unit

Control Diagnosis signal

Brake switch 1 (brake switch)

Brake switch 2 (stop light switch)

B135

25







B136

33

0 or 5

0 or 5

Waveform

B135

10

0 or 10 — 13

12 — 14



15

When brake pedal is depressed: 0 When brake pedal is released: 10 — 13

When brake pedal is depressed: 0 When brake pedal is released: 12 — 14



3

When brake pedal is depressed: 10 — 13 When brake pedal is released: 0

When brake pedal is depressed: 12 — 14 When brake pedal is released: 0



B136

B136

EN(H6DO)(diag)-20

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) Signal (V) Ignition SW ON Engine ON (idling) (engine OFF) When operating When operating nothing: 3.5 — 4.5 nothing: 3.5 — 4.5 When operating When operating RES/ACC: 2.5 — 3.5 RES/ACC: 2.5 — 3.5 When operating vehi- When operating vehicle distance setting: cle distance setting: 1.5 — 2.5 1.5 — 2.5 When operating SET/ When operating SET/ COAST: 0.5 — 1.5 COAST: 0.5 — 1.5 When operating When operating CANCEL: 0 — 0.5 CANCEL: 0 — 0.5 ON: 0 ON: 0 OFF: 5 OFF: 5 0 0.6

Connector No.

Terminal No.

Cruise control command switch

B136

12

Cruise control main switch

B136

13

Signal (+) Intake oil flow control solenoid Signal (–) valve LH Signal (+) Intake oil flow control solenoid Signal (–) valve RH Exhaust oil Signal (+) flow control solenoid Signal (–) valve LH Exhaust oil Signal (+) flow control solenoid Signal (–) valve RH Oil temperature sensor signal Oil level switch Power steering oil pressure switch

B134

17

B134

16

0

0



B134

34

0

0.6



B134

27

0

0



B134

5

0

1.9



B134

14

0

0



B134

7

0

1.9



B134

15

0

0



B137 B136

21 26

1.0 — 1.4 0

1.0 — 1.4 0

After engine is warmed up. Oil level Low: 10 — 14

B137

28

ON: 1 or less OFF: 10 — 13

ON: 1 or less OFF: 12 — 14



SSM communication line

B135

14

1 or less ←→ 4 or more

1 or less ←→ 4 or more



Clutch switch

B135

9

10 — 13

12 — 14



Ground

Engine 1 Engine 2 Engine 3 Engine 4 Engine 5 Engine 6 Body

B134 B135 B134 B134 B134 B137 B137 B137 B136

29 30 6 4 3 1 3 5 4

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

— — — — — — — — —

(Hi) (Lo)

B136 B136

17 28

Fuel tank pressure sensor

B136

21

2.3 — 2.7

2.3 — 2.7

Value after detaching and attaching the fuel filler cap

Drain valve

B135

4

ON: 1 or less OFF: 10 — 13

ON: 1 or less OFF: 12 — 14



Fuel temperature sensor

B136

23

2.5 — 3.8

2.5 — 3.8

Outside temperature: 25°C (77°F)

Description

Sensor

CAN communication

Pulse signal Pulse signal

EN(H6DO)(diag)-21

Note



— —

— —

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

Input/output name: • Crankshaft position sensor • Intake camshaft position sensor RH • Intake camshaft position sensor LH • Exhaust camshaft position sensor RH • Exhaust camshaft position sensor LH Measuring condition: • After warming-up • At idling

CRANKSHAFT POSITION SENSOR

0

ONE CRANKSHAFT ROTATION

INTAKE CAMSHAFT POSITION SENSOR RH

0

ONE CAMSHAFT ROTATION

INTAKE CAMSHAFT POSITION SENSOR LH

0

EXHAUST CAMSHAFT POSITION SENSOR RH

0

EXHAUST CAMSHAFT POSITION SENSOR LH

0 10 ms 5V

EN(H6DO)(diag)-22

EN-07432

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) F/B FUSE No. 4 DATA LINK CONNECTOR C2

M/B FUSE No. 12

B9

C16

STARTER MOTOR

B14

IGNITION SWITCH

DELIVERY (TEST) MODE FUSE

B26

F/B FUSE No. 21

C34

INHIBITOR RELAY

STARTER RELAY C4 JOINT CONNECTOR C35

TCM

B23 C30

F/B FUSE No. 12

B21

FUEL PUMP RELAY

B31 FUEL PUMP CONTROL UNIT

M/B FUSE No. 20

ACCELERATOR PEDAL POSITION SENSOR

C33 B10

B29 B22

7

FUEL PUMP ASSY FUEL TEMPERATURE SENSOR

C23

1

1 JOINT CONNECTOR

POWER STEERING OIL PRESSURE SWITCH

B30 D28

2 3 4 5

OIL LEVEL SWITCH

6

C26

EN-07839

EN(H6DO)(diag)-23

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS) M/B FUSE No. 15 M/B FUSE No. 16 M/B FUSE No. 13 M/B FUSE No. 14 A/F, OXYGEN SENSOR RELAY

IG RELAY

MAIN RELAY

A21

D7

IGNITION COIL No. 1

C1 ELECTRONIC THROTTLE CONTROL RELAY B7

A22 IGNITION COIL No. 2

B17

A31 IGNITION COIL No. 3 A32 IGNITION COIL No. 4

B13 A25

IGNITION COIL No. 5 A26 PURGE CONTROL SOLENOID VALVE

IGNITION COIL No. 6

D6

10 DRAIN VALVE

B4 B15 B33

INTAKE CAMSHAFT POSITION SENSOR LH

D16 A17 A16

INTAKE CAMSHAFT POSITION SENSOR RH

D24

A34 A27

EXHAUST CAMSHAFT POSITION SENSOR LH

EXHAUST CAMSHAFT POSITION SENSOR RH

8

COMBINATION METER

D29

A5 A14

D23 D30

A7 A15

INTAKE OIL FLOW CONTROL SOLENOID VALVE LH

INTAKE OIL FLOW CONTROL SOLENOID VALVE RH

EXHAUST OIL FLOW CONTROL SOLENOID VALVE LH

EXHAUST OIL FLOW CONTROL SOLENOID VALVE RH

9 EN-07840

EN(H6DO)(diag)-24

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

6

9 FUEL INJECTOR No. 1

A10

A18 FUEL INJECTOR No. 2

A11

A28

FUEL INJECTOR No. 3

A12

11

ELECTRONIC THROTTLE CONTROL

A2 A1 FUEL INJECTOR No. 4

A13

A19 A29

FUEL INJECTOR No. 5

A23 D20

FUEL INJECTOR No. 6

MANIFOLD ABSOLUTE PRESSURE SENSOR

A24 D22

A8

ENGINE COOLANT TEMPERATURE SENSOR

D21 D8

OIL TEMPERATURE SENSOR

D2

KNOCK SENSOR No. 1

D4

KNOCK SENSOR No. 2

A9

EGR VALVE A20

A30

D17 CRANKSHAFT POSITION SENSOR

D25 D31

9

12 EN-07841

EN(H6DO)(diag)-25

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Engine Control Module (ECM) I/O Signal ENGINE (DIAGNOSTICS)

2

8

B2 B1

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

9

C31 C11

FRONT OXYGEN (A/F) SENSOR LH

B8 B20

C10 C22 C19 C18

3

7 FUEL TANK PRESSURE SENSOR

FRONT OXYGEN (A/F) SENSOR RH

C6 C5 C21

4

C9 B5

RADIATOR FAN CONTROL UNIT

REAR OXYGEN SENSOR LH

B11

B28

MAIN FAN RELAY

B12

5 C20 REAR OXYGEN SENSOR RH

C13

B6

CRUISE CONTROL SWITCH C12

STOP LIGHT SWITCH

C3

11

12

10

A6 BRAKE SWITCH

C15

A4 D1 A3

BODY INTEGRATED UNIT (IMMOBILIZER)

B25

D5 D3

C17 BODY INTEGRATED UNIT (CAN COMMUNICATION)

C28

ENGINE GROUND

EN(H6DO)(diag)-26

EN-07842

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Engine Condition Data ENGINE (DIAGNOSTICS)

6. Engine Condition Data A: ELECTRICAL SPECIFICATION Contents

Specification 17.9 — 38.8(%): Idling 16.6 — 33.7(%): 2,500 rpm racing

Engine load

Measuring condition: • After engine is warmed up. • Place the select lever in “P” range or “N” range. • Turn the A/C to OFF. • Turn all the accessory switches to OFF.

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Data Link Connector ENGINE (DIAGNOSTICS)

7. Data Link Connector A: NOTE This connector is used for Subaru Select Monitor. CAUTION: Do not connect any scan tools other than Subaru Select Monitor or general scan tool because the circuit for Subaru Select Monitor may be damaged.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

EN-07824

Terminal No. 1 2 3 4 5 6 7 8

Contents Empty Empty Empty Ground Ground CAN communication (Hi) Subaru Select Monitor signal Empty

Terminal No. 9 10 11 12 13 14 15 16

EN(H6DO)(diag)-28

Contents Empty Empty Empty Empty Empty CAN communication (Lo) Empty Power supply

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General Scan Tool ENGINE (DIAGNOSTICS)

8. General Scan Tool A: OPERATION 1. HOW TO USE GENERAL SCAN TOOL 1) Prepare a scan tool (general scan tool) required by SAE J1978. 2) Connect the general scan tool to the data link connector located in the lower portion of the instrument panel (on the driver’s side).

EN-07712

3) Using the general scan tool, call up each data. General scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic data (2) MODE $02: Powertrain freeze frame data (3) MODE $03: Emission-related powertrain DTC (4) MODE $04: Clear/Reset emission-related diagnostic information (5) MODE $06: Request on-board monitoring test results for intermittently monitored systems (6) MODE $07: Request on-board monitoring test results for continuously monitored systems (7) MODE $09: Request vehicle information Read out the data according to repair procedures. (For detailed operation procedure, refer to the general scan tool operation manual.) NOTE: For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”.

EN(H6DO)(diag)-29

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General Scan Tool ENGINE (DIAGNOSTICS)

2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA) Refer to data denoting the current operating condition of analog input/output, digital input/output or the powertrain system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. PID $01 $03 $04 $05 $06 $07 $08 $09 $0B $0C $0D $0E $0F $10 $11 $13 $15 $15 $19 $19 $1C $1F $21

Data Number of emission-related powertrain DTC and malfunction indicator light status Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim (Bank 1) Long term fuel trim (Bank 1) Short term fuel trim (Bank 2) Long term fuel trim (Bank 2) Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance Intake air temperature Intake air amount Throttle valve opening angle Air fuel ratio sensor Oxygen sensor output voltage (Bank 1 Sensor 2) Oxygen sensor correction (Bank 2 Sensor 1) Oxygen sensor output voltage (Bank 2 Sensor 2) Oxygen sensor correction (Bank 2 Sensor 2) On-board diagnostic system Elapsed time after starting the engine Driving distance after the malfunction indicator light illuminates

$24

Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (Bank 1)

– and V

$28

Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (Bank 2)

– and V

$2C $2D $2E $2F $30 $31 $32 $33 $34 $34 $38 $38 $3C $3D $41 $42 $43 $44 $45

Target EGR EGR deviation Evaporative purge Fuel level Number of warm ups after DTC clear Driving distance after DTC clear Fuel tank pressure Atmospheric pressure A/F sensor lambda value (Bank 1 Sensor 1) A/F sensor current value (Bank 1 Sensor 1) A/F sensor lambda value (Bank 2 Sensor 1) A/F sensor current value (Bank 2 Sensor 1) Catalytic temperature #1 Catalytic temperature #2 Diagnostic monitor of each drive cycle ECM power voltage Absolute load A/F target lambda Relative throttle opening angle

EN(H6DO)(diag)-30

Unit of measure — — % °C % % % % kPa rpm MPH ° °C g/s % — V % V % — sec miles

% % % % — miles Pa kPa — mA — mA °C °C — V % — %

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General Scan Tool ENGINE (DIAGNOSTICS) PID $46 $47 $49 $4A $4C $4D $4E $51 $5A $65

Data Ambient temperature Absolute throttle opening angle 2 Absolute acceleration opening angle 1 Absolute acceleration opening angle 2 Target throttle opening angle Engine operating time while malfunction indicator light lit Elapsed time after DTC clear Fuel used Relative acceleration opening angle Neutral status

Unit of measure °C % % % % min min — % —

NOTE: Refer to general scan tool manufacturer’s instruction manual to access the generic OBD-II PID (MODE $01).

EN(H6DO)(diag)-31

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General Scan Tool ENGINE (DIAGNOSTICS)

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) Refer to data denoting the operating condition when trouble is sensed by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table. PID $02 $03 $04 $05 $06 $07 $08 $09 $0B $0C $0D $0E $0F $10 $11 $13 $15 $15 $19 $19 $1C $1F $2C $2D $2E

Data DTC that caused the freeze frame data storage required by CARB Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim (Bank 1) Long term fuel trim (Bank 1) Short term fuel trim (Bank 2) Long term fuel trim (Bank 2) Intake manifold absolute pressure Engine speed Vehicle speed Ignition timing advance Intake air temperature Intake air amount Throttle valve opening angle Air fuel ratio sensor Oxygen sensor output voltage (Bank 1 Sensor 2) Oxygen sensor correction (Bank 2 Sensor 1) Oxygen sensor output voltage (Bank 2 Sensor 2) Oxygen sensor correction (Bank 2 Sensor 2) On-board diagnostic system Elapsed time after starting the engine Target EGR EGR deviation Evaporative purge

$2F $32 $33 $42 $43 $44 $45 $46 $47 $49 $4A $4C $65

Fuel level Fuel tank pressure Atmospheric pressure ECM power voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute acceleration opening angle 1 Absolute acceleration opening angle 2 Target throttle opening angle Neutral status

Unit of measure — — % °C % % % % kPa rpm MPH ° °C g/s % — V % V % — sec % % % % Pa kPa V % — % °C % % % % —

NOTE: Refer to general scan tool manufacturer’s operation manual to access freeze frame data (MODE $02).

4. MODE $03 (EMISSION-RELATED POWERTRAIN DTC) Refer to “List of Diagnostic Trouble Code (DTC)” for information about data denoting emission-related powertrain DTC.

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General Scan Tool ENGINE (DIAGNOSTICS)

5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION) Refer to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic information). NOTE: • Refer to general scan tool manufacturer’s instruction manual to clear the emission-related diagnostic information (MODE $04). • Initial diagnosis of electronic throttle control is performed after memory clearance. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine.

6. MODE $06 Refer to test value of troubleshooting and data of test limit indicated on the support data bit sequence table. A list of the support data is shown in the following table. OBDMID

$01

$02

$05

$06

$21 $31

$35

$36

$39

TID $81 $82 $83 $84 $85 $86 $87 $88 $07 $08 $A5 $05 $06 $81 $82 $83 $84 $85 $86 $87 $88 $07 $08 $A5 $05 $06 $89 $8A $8B $8C $8D $8E $8B $8C $8D $8E $93

SID $0A $8D $14 $1E $1E $20 $0B $0B $0B $0B $0B $10 $10 $0A $8D $14 $1E $1E $20 $0B $0B $0B $0B $0B $10 $10 $20 $FD $9D $9D $9D $9D $9D $9D $9D $9D $FE

Diagnostic item A/F sensor continuity failure (Bank 1 Sensor 1)

A/F sensor range failure (Bank 1 Sensor 1) A/F sensor response failure (Bank 1 Sensor 1) Oxygen sensor circuit failure (Bank 1 Sensor 2)

Oxygen sensor drop failure (Bank 1 Sensor 2)

Oxygen sensor response failure (Bank 1 Sensor 2)

A/F sensor continuity failure (Bank 2 Sensor 1)

A/F sensor range failure (Bank 2 Sensor 1) A/F sensor response failure (Bank 2 Sensor 1) Oxygen sensor circuit failure (Bank 2 Sensor 2)

Oxygen sensor drop failure (Bank 2 Sensor 2)

Oxygen sensor response failure (Bank 2 Sensor 2) Catalyst deterioration diagnosis (Bank 1) EGR system diagnosis

VVT monitor bank 1

VVT monitor bank 2

Evaporative emission control system (Cap off)

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General Scan Tool ENGINE (DIAGNOSTICS) OBDMID $3B $3C $3D $41

$42

$45

$46 $A1 $A2 $A3 $A4 $A5 $A6 $A7

TID

SID

$94 $95 $96 $97 $98 $99 $9A $9B $9C $9D $99 $9A $9B $9C $9D $0B $0C $0B $0C $0B $0C $0B $0C $0B $0C $0B $0C $0B $0C

$FE $FE $FE $FE $FE $24 $24 $14 $24 $24 $24 $24 $14 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24 $24

Diagnostic item Evaporative emission control system (0.04 inch leak) Evaporative emission control system (0.02 inch leak) Evaporative emission control system (Purge flow) A/F sensor heater failure (Bank 1 Sensor 1) A/F sensor heater characteristics failure (Bank 1 Sensor 1) Oxygen sensor heater failure (Bank 1 Sensor 2) A/F sensor heater failure (Bank 2 Sensor 1) A/F sensor heater characteristics failure (Bank 2 Sensor 1) Oxygen sensor heater failure (Bank 2 Sensor 2) Misfire monitoring (All cylinders) Misfire monitoring (#1 cylinder) Misfire monitoring (#2 cylinder) Misfire monitoring (#3 cylinder) Misfire monitoring (#4 cylinder) Misfire monitoring (#5 cylinder) Misfire monitoring (#6 cylinder)

7. MODE $07 Refer to the data of DTC (pending code) for troubleshooting result about emission in the first time.

8. MODE $09 Refer to the data of vehicle specification (V.I.N., calibration ID, diagnosis frequency, etc.).

EN(H6DO)(diag)-34

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Subaru Select Monitor ENGINE (DIAGNOSTICS)

9. Subaru Select Monitor A: OPERATION 1. HOW TO USE THE SUBARU SELECT MONITOR NOTE: For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

EN(H6DO)(diag)-35

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Subaru Select Monitor ENGINE (DIAGNOSTICS)

2. READ CURRENT DATA FOR ENGINE (NORMAL MODE) NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • A list of the support data is shown in the following table. Contents Engine load

Display Engine Load

Engine coolant temperature signal

Coolant Temp.

A/F correction #1 A/F learning #1 A/F correction #2 A/F learning #2

A/F Correction #1 A/F Learning #1 A/F Correction #2 A/F Learning #2

Intake manifold absolute pressure

Mani. Absolute Pressure

Engine speed signal

Engine Speed

Meter vehicle speed signal Ignition timing signal Intake air temperature signal

Vehicle Speed Ignition Timing Intake Air Temp.

Intake air amount

Mass Air Flow

Throttle opening angle signal Front oxygen sensor voltage value 1 Front oxygen sensor voltage value 2 Battery voltage Mass air flow voltage Injection 1 pulse width Injection 2 pulse width

Throttle Opening Angle Front O2 Sensor #1 Front O2 Sensor #2 Battery Voltage Air Flow Sensor Voltage Fuel Injection #1 Pulse Fuel Injection #2 Pulse

Atmospheric pressure signal

Atmosphere Pressure

Intake manifold relative pressure

Mani. Relative Pressure

mmHg, kPa, inHg or psig

Learned ignition timing Acceleration opening angle signal Fuel temperature signal

Learned Ignition Timing Accel. Opening Angle Fuel Temp.

deg % °C or °F

Radiator fan output

Radiator Fan Control

Purge control solenoid valve duty ratio Number of EGR steps Fuel pump duty ratio AVCS advance angle amount RH AVCS advance angle amount LH Oil flow control solenoid valve duty ratio RH Oil flow control solenoid valve duty ratio LH Oil flow control solenoid valve current RH Oil flow control solenoid valve current LH Front oxygen (A/F) sensor current value 1 Front oxygen (A/F) sensor current value 2 Front oxygen (A/F) sensor resistance value 1

CPC Valve Duty Ratio No. of EGR steps Fuel Pump Duty VVT Adv. Ang. Amount R VVT Adv. Ang. Amount L OCV Duty R OCV Duty L OCV Current R OCV Current L A/F Sensor #1 Current A/F Sensor #2 Current A/F Sensor #1 Resistance

EN(H6DO)(diag)-36

Unit of measure %

% % % %

Note (at idling) 2.4% ≥ 85°C or 185°F (after warm-up) –10% — +10% –10% — +10% –10% — +10% –10% — +10%

mmHg, kPa, inHg or psig

210 mmHg, 28 kPa, 8.3 inHg or 4.1 psig

°C or °F

rpm km/h or MPH deg °C or °F g/s or lb/m % V V V V ms ms mmHg, kPa, inHg or psig

% % STEP % deg deg % % mA mA mA mA Ω

600 — 800 rpm (after warm-up) 0 km/h or 0 MPH 13 — 15 deg (Ambient air temperature) 2.5 g/s — 5.0 g/s or 0.31 lb/m — 0.71 lb/m 2% 0.900 V 0.900 V 12 — 13 V 1.2 — 1.3 V 2.5 ms — 3.5 ms 2.5 ms — 3.5 ms (Atmospheric pressure) (Air intake absolute pressure — Atmospheric pressure) +0.0 deg 0% +28°C or +82°F 0% (Water temperature 90°C (194°F) when air conditioner is OFF) 18% 0 STEP 33% 0 deg — +1 deg 0 deg — +1 deg 9.4% 9.4% 64 mA 64 mA 0.0 mA 0.0 mA 31 Ω

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents Front oxygen (A/F) sensor resistance value 2 Front oxygen (A/F) sensor output lambda 1 Front oxygen (A/F) sensor output lambda 2 A/F correction #3 A/F learning #3 Throttle motor duty Throttle motor voltage Sub throttle sensor voltage Main throttle sensor voltage Sub accelerator sensor voltage Main acceleration sensor voltage Memory vehicle speed A/F correction #4 A/F learning #4 Fuel level sensor resistance

Display A/F Sensor #2 Resistance A/F Sensor #1 A/F Sensor #2 A/F Correction #3 A/F Learning #3 Throttle Motor Duty Throttle Motor Voltage Sub-Throttle Sensor Main-Throttle Sensor Sub-Accelerator Sensor Main-Accelerator Sensor Memorized Cruise Speed A/F Correction #4 A/F Learning #4 Fuel level resistance

Engine oil temperature

Oil Temperature

Exhaust AVCS retard angle amount RH Exhaust AVCS retard angle amount LH Exhaust oil flow control solenoid valve duty ratio RH Exhaust oil flow control solenoid valve duty ratio LH Exhaust oil flow control solenoid valve current RH Exhaust oil flow control solenoid valve current LH #1 cylinder roughness monitor #2 cylinder roughness monitor #3 cylinder roughness monitor #4 cylinder roughness monitor #5 cylinder roughness monitor #6 cylinder roughness monitor Knock sensor correction

Exh. VVT Retard Ang. R Exh. VVT Retard Ang. L Exh. OCV Duty R Exh. OCV Duty L Exh. OCV Current R Exh. OCV Current L Roughness Monitor #1 Roughness Monitor #2 Roughness Monitor #3 Roughness Monitor #4 Roughness Monitor #5 Roughness Monitor #6 Knocking Correction

Fuel tank pressure signal

Fuel Tank Pressure

AT/MT identification D-check require Flag

AT Vehicle ID Signal D-check Require Flag

Delivery (test) mode terminal Neutral position switch signal Idle switch signal Ignition switch signal Power steering switch signal Air conditioning switch signal Starter switch signal Front oxygen monitor 1 Front oxygen monitor 2 Knocking signal Crankshaft position sensor signal Camshaft position sensor signal Rear defogger switch signal Blower fan switch signal Light switch signal

Unit of measure Ω — — % % % V V V V V km/h or MPH % % Ω

Note (at idling) 31 Ω 1.01 1.01 0% — 1% 0.0% –20% — +20% (Battery voltage) 1.4 V — 1.5 V 0.62 V — 0.70 V 1.0 V — 1.2 V 0.9 V — 1.1 V 0 km/h or 0 MPH –1% — 1% 0.0% 4 — 96 Ω

deg deg % % mA mA — — — — — — deg mmHg, kPa, inHg or psig — —

≥ 85°C or 185°F (after warm-up) 0 deg — +1 deg 0 deg — +1 deg 9.4% 9.4% 64 mA 64 mA 0 0 0 0 0 0 0 deg 7.5 mmHg, 1 kPa, 0.3 inHg or 0.14 psi AT vehicle OFF

Delivery Mode Connector (Test Mode Connector)



OFF

Neutral Position Switch Idle Switch Signal Ignition Switch P/S Switch Signal A/C Switch Starter Switch Front O2 #1 Rich Signal Front O2 #2 Rich Signal Knocking Signal Crankshaft Position Sig. Camshaft Position Sig. Rear Defogger SW Blower Fan SW Light Switch

— — — — — — — — — — — — — —

ON ON ON OFF (when OFF) OFF (when OFF) OFF Rich, Lean Rich, Lean OFF ON ON OFF (when OFF) OFF (when OFF) OFF (when OFF)

EN(H6DO)(diag)-37

°C or °F

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents Drain valve signal AT coordinate retard angle demand signal AT coordinate fuel cut demand signal Vehicle dynamics control (VDC) torque down prohibition output

Display Vent. Solenoid Valve Retard Signal from AT Fuel Cut signal from AT

Unit of measure — — —

Note (at idling) OFF (when OFF) OFF OFF

Ban of Torque Down



ON

Vehicle dynamics control (VDC) torque down demand

Request Torque Down VDC



OFF

AT coordinate permission signal Electronic throttle control motor relay signal Stop light switch signal

Torque permission signal ETC Motor Relay Stop Light Switch

— — —

ON ON OFF (when brake is OFF)

SET/COAST switch signal

SET/COAST Switch



OFF (when levers are not operated)

RESUME/ACCEL switch signal

RESUME/ACCEL Switch



Brake switch signal

Brake Switch



Main switch signal

Main Switch



Cruise control cancel switch signal

CC Cancel SW



Malfunction indicator light on flag Oil level switch signal

MIL On Flag Oil level switch

— —

EN(H6DO)(diag)-38

OFF (when levers are not operated) OFF (when brake is OFF) OFF (when levers are not operated) OFF (when levers are not operated) Light OFF HIGH level

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Subaru Select Monitor ENGINE (DIAGNOSTICS)

3. READ CURRENT DATA FOR ENGINE (OBD MODE) NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • A list of the support data is shown in the following table. Contents Number of diagnosis code Condition of malfunction indicator light Monitoring test of misfire Monitoring test of misfire

Display Number of Diag. Code: MI(MIL) Misfire monitoring (Supp) Misfire monitoring (Rdy) Fuel system monitoring (Supp)

Monitoring test of fuel system

Referential value (at idling) 0 OFF YES YES

Unit of measure — — — —

YES



Monitoring test of fuel system

Fuel system monitoring (Rdy)

YES



Monitoring test of comprehensive component

Component monitoring (Supp)

YES



YES



YES



NO NO N/A

— — —

Component monitoring (Rdy) Catalyst Diagnosis (Supp) Catalyst Diagnosis (Rdy) Heated catalyst (Supp) Heated catalyst (Rdy)

Monitoring test of comprehensive component Test of catalyst Test of catalyst Test of heating-type catalyst Test of heating-type catalyst Test of evaporative emission purge control system

Evaporative purge system (Supp)

YES



Test of evaporative emission purge control system

Evaporative purge system (Rdy)

NO



Secondary air system test

Secondary air system (Supp)

NO



Secondary air system test

Secondary air system (Rdy)

N/A



Test of air conditioning system refrigerant

A/C system refrigerant (Supp)

NO



Test of air conditioning system refrigerant

A/C system refrigerant (Rdy)

N/A



YES NO

— —

YES



NO



EGR system (Supp) EGR system (Rdy) Fuel system for Bank 1 Fuel system for Bank 2 Calculated load value Coolant Temp.

YES NO Cl_normal Cl_normal 21.0 91

— — — — % °C

Short term fuel trim B1

17.2

%

Long term fuel trim B1

5.5

%

Short term fuel trim B2

17.2

%

Long term fuel trim B2

5.5

%

Test of oxygen sensor Test of oxygen sensor

Oxygen sensor (Supp) Oxygen sensor (Rdy) O2 Heater Diagnosis (Supp)

Test of oxygen sensor heater

O2 Heater Diagnosis (Rdy)

Test of oxygen sensor heater Test of EGR system Test of EGR system Air fuel ratio control system for bank 1 Air fuel ratio control system for bank 2 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim by front oxygen (A/F) sensor (Bank 1) Short term fuel trim by front oxygen (A/F) sensor (Bank 2) Long term fuel trim by front oxygen (A/F) sensor (Bank 2)

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal #1 Cylinder ignition timing Intake air temperature signal Intake air amount Throttle position signal Oxygen sensor (Bank 1 Sensor 2) A/F correction (Bank 1 Sensor 2) Oxygen sensor (Bank 2 Sensor 2) A/F correction (Bank 2 Sensor 2) On-board diagnostic system Front oxygen (A/F) sensor (Bank 1 Sensor 1) Oxygen sensor (Bank 1 Sensor 2) Front oxygen (A/F) sensor (Bank 2 Sensor 1) Oxygen sensor (Bank 2 Sensor 2) Elapsed time after engine start Travel distance after the malfunction indicator light illuminates

Display Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Oxygen sensor #12 Short term fuel trim #12 Oxygen sensor #22 Short term fuel trim #22 OBD System Oxygen sensor #11 Oxygen sensor #12 Oxygen sensor #21 Oxygen sensor #22 Time Since Engine Start

Referential value (at idling) 233 700 0 16.5 54 2.8 13 0.1 — 0.7 0.0 0.1 — 0.7 0.0 OBD/OBD2 Supported Supported Supported Supported —

Unit of measure mmHg rpm km/h ° °C g/s % V % V % — — — — — sec

Lighted MI lamp history



km

A/F lambda signal (Bank 1 Sensor 1) A/F sensor output signal (Bank 1 Sensor 1) A/F lambda signal (Bank 2 Sensor 1) A/F sensor output signal (Bank 2 Sensor 1) Target EGR EGR deviation Evaporative purge Fuel level signal Number of warm ups after DTC clear Travel distance after DTC clear Fuel tank pressure signal Atmospheric pressure signal A/F lambda signal (Bank 1 Sensor 1) A/F sensor current (Bank 1 Sensor 1) A/F lambda signal (Bank 2 Sensor 1) A/F sensor current (Bank 2 Sensor 1) Catalyst temperature #1 Catalyst temperature #2

A/F Sensor #11 A/F Sensor #11 A/F Sensor #21 A/F Sensor #21 Commanded EGR EGR Error Commanded Evap Purge Fuel Level Number of warm-ups Meter since DTC cleared Fuel Tank Pressure Atmosphere Pressure A/F Sensor #11 A/F Sensor #11 A/F Sensor #21 A/F Sensor #21 Catalyst Temperature #11 Catalyst Temperature #21 Misfire monitoring (Enable)

1.001 2.805 1.001 2.805 0 0.0 0 — — — 8.8 Atmospheric pressure 0.999 0.02 0.999 0.02 — —

— V — V % % % % — km mmHg mmHg — mA — mA °C °C

YES



Monitoring test of misfire Monitoring test of misfire

Misfire monitoring (Comp)

NO



Monitoring test of fuel system

Fuel system monitoring (Enable)

YES



Monitoring test of fuel system

Fuel system monitoring (Comp)

NO



Monitoring test of comprehensive component

Component monitoring (Enable)

YES



Monitoring test of comprehensive component

Component monitoring (Comp)

NO



Test of catalyst

Catalyst Diagnosis (Enable)

YES



EN(H6DO)(diag)-40

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Subaru Select Monitor ENGINE (DIAGNOSTICS) Contents

Display Catalyst Diagnosis (Comp)

Test of catalyst Test of heating-type catalyst Test of heating-type catalyst Test of evaporative emission purge control system

Heated catalyst (Enable) Heated catalyst (Comp) Evaporative purge system (Enable)

Referential value (at idling)

Unit of measure

NO



N/A N/A

— —

YES



Test of evaporative emission purge control system

Evaporative purge system (Comp)

NO



Secondary air system test

Secondary air system (Enable)

N/A



Secondary air system test

Secondary air system (Comp)

N/A



Test of air conditioning system refrigerant

A/C system refrigerant (Enable)

N/A



N/A



YES NO

— —

A/C system refrigerant (Comp) Oxygen sensor (Enable) Oxygen sensor (Comp)

Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor Test of oxygen sensor heater

O2 Heater Diagnosis (Enable)

YES



Test of oxygen sensor heater

O2 Heater Diagnosis (Comp)

NO



YES NO 13.789 22 0.976 2 Ambient air temperature 32 13 13 0

— — V % — % °C % % % %



min

— GAS 0 NEUT

min — % —

Test of EGR system Test of EGR system ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Engine operating time while malfunction indicator light lit

EGR system (Enable) EGR system (Comp) Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont.

Elapsed time after DTC clear Type of fuel Relative acceleration opening angle Neutral condition

Time since DTC cleared Type of fuel Relative Accelera. Pos. AT drive status

Time while MIL lighted

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Subaru Select Monitor ENGINE (DIAGNOSTICS)

4. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE) NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • A list of the support data is shown in the following table. Description DTC of freeze frame data Air fuel ratio control system for bank 1 Air fuel ratio control system for bank 2 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor (Bank 1) Long term fuel trim by front oxygen (A/F) sensor (Bank 1) Short term fuel trim by front oxygen (A/F) sensor (Bank 2) Long term fuel trim by front oxygen (A/F) sensor (Bank 2) Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal Ignition timing adv. #1 Intake air temperature Amount of intake air Throttle valve angle Oxygen sensor #12 A/F correction value #12 Oxygen sensor #22 A/F correction value #22 On-board diagnostic system Oxygen sensor #11 Oxygen sensor #12 Oxygen sensor #21 Oxygen sensor #22 Elapsed time after engine start Target EGR EGR deviation Evaporative purge Fuel level signal Fuel tank pressure signal Atmospheric pressure ECM power supply voltage Absolute load A/F target lambda Relative throttle opening angle Ambient temperature Absolute throttle opening angle 2 Absolute accelerator opening angle 1 Absolute accelerator opening angle 2 Target throttle opening angle Neutral condition

Display Freeze frame data Fuel system for Bank 1 Fuel system for Bank 2 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Short term fuel trim B2 Long term fuel trim B2 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle Oxygen sensor #12 Short term fuel trim #12 Oxygen sensor #22 Short term fuel trim #22 OBD System Oxygen sensor #11 Oxygen sensor #12 Oxygen sensor #21 Oxygen sensor #22 Time Since Engine Start Commanded EGR EGR Error Commanded Evap Purge Fuel Level Fuel Tank Pressure Atmosphere Pressure Control module voltage Absolute Load Value Target Equivalence Ratio Relative Throttle Pos. Ambient Temperature Absolute Throttle Pos.#2 Accelerator Pedal Pos.#1 Accelerator Pedal Pos.#2 Target Throt. Act. Cont. AT drive status

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Unit of measure — — — % °C or °F % % % % mmHg, kPa, inHg or psig rpm km/h or MPH ° °C or °F g/s % V % V % — — — — — sec % % % % mmHg, kPa, inHg or psig mmHg, kPa, inHg or psig V % — % °C or °F % % % % —

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Subaru Select Monitor ENGINE (DIAGNOSTICS)

5. V.I.N. REGISTRATION 1) On «Main Menu» display, select {Each System Check}. 2) On «System Selection Menu» display, select {Engine Control System}. 3) Click the [OK] button after the information of engine type has been displayed. 4) On «Engine Diagnosis» display, select {Entry VIN}. 5) Perform the procedures shown on the display screen.

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Read Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10.Read Diagnostic Trouble Code (DTC) A: OPERATION 1. SUBARU SELECT MONITOR (NORMAL MODE) NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”.

2. GENERAL SCAN TOOL Refer to the data denoting emission-related powertrain DTC. For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”. NOTE: Refer to the general scan tool manufacturer’s operation manual to access powertrain DTC (MODE $03).

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Inspection Mode ENGINE (DIAGNOSTICS)

11.Inspection Mode A: PROCEDURE Perform the diagnosis shown in the following DTC table. When performing the diagnosis not listed in “List of Diagnostic Trouble Code (DTC)”, refer to the item on the drive cycle. DTC P0011 P0014 P0016 P0017 P0018 P0019 P0021 P0024 P0031 P0032 P0037 P0038 P0051 P0052 P0057 P0058 P0102 P0103 P0107 P0108 P0112 P0113 P0117 P0118 P0122 P0123 P0131 P0132 P0137 P0138 P0140 P0151 P0152 P0157 P0158 P0160 P0182 P0183 P0197 P0198 P0222 P0223

Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Exhaust AVCS System 1 (Range/Performance) Crankshaft Position - Camshaft Position Correlation (Bank1) Crank and Cam Timing B System Failure (Bank 1) Crankshaft Position - Camshaft Position Correlation (Bank2) Crank and Cam Timing B System Failure (Bank 2) Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 2) Exhaust AVCS System 2 (Range/Performance) HO2S Heater Control Circuit Low (Bank 1 Sensor 1) HO2S Heater Control Circuit High (Bank 1 Sensor 1) HO2S Heater Control Circuit Low (Bank 1 Sensor 2) HO2S Heater Control Circuit High (Bank 1 Sensor 2) HO2S Heater Control Circuit Low (Bank 2 Sensor 1) HO2S Heater Control Circuit High (Bank 2 Sensor 1) HO2S Heater Control Circuit Low (Bank 2 Sensor 2) HO2S Heater Control Circuit High (Bank 2 Sensor 2) Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input Manifold Absolute Pressure/Barometric Pressure Circuit High Input Intake Air Temperature Sensor 1 Circuit Low Intake Air Temperature Sensor 1 Circuit High Engine Coolant Temperature Circuit Low Engine Coolant Temperature Circuit High Throttle/Pedal Position Sensor/Switch “A” Circuit Low Throttle/Pedal Position Sensor/Switch “A” Circuit High O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 1) O2 Sensor Circuit High Voltage (Bank 2 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 2) O2 Sensor Circuit High Voltage (Bank 2 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 2) Fuel Temperature Sensor “A” Circuit Low Input Fuel Temperature Sensor “A” Circuit High Input Engine Oil Temperature Sensor Low Engine Oil Temperature Sensor High Throttle/Pedal Position Sensor/Switch “B” Circuit Low Throttle/Pedal Position Sensor/Switch “B” Circuit High

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Condition — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

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Inspection Mode ENGINE (DIAGNOSTICS) DTC P0230 P0327 P0328 P0332 P0333 P0335 P0336 P0340 P0345 P0365 P0390 P0447 P0448 P0452 P0453 P0458 P0462 P0463 P0500 P0512 P0513 P0604 P0605 P0607 P0638 P0700 P1152 P1153 P1154 P1155 P1160 P1518 P1560 P1570 P1571 P1572 P1574 P1576 P1577 P1578 P2088 P2089 P2090 P2091 P2092 P2093 P2094 P2095 P2101 P2102

Item Fuel Pump Primary Circuit Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor) Knock Sensor 1 Circuit High (Bank 1 or Single Sensor) Knock Sensor 2 Circuit Low (Bank 2) Knock Sensor 2 Circuit High (Bank 2) Crankshaft Position Sensor “A” Circuit Crankshaft Position Sensor “A” Circuit Range/Performance Camshaft Position Sensor “A” Circuit (Bank 1 or Single Sensor) Camshaft Position Sensor “A” Circuit (Bank 2) Camshaft Position Sensor “B” Circuit (Bank 1) Camshaft Position Sensor “B” Circuit (Bank 2) Evaporative Emission Control System Vent Control Circuit Open Evaporative Emission Control System Vent Control Circuit Shorted Evaporative Emission Control System Pressure Sensor Low Input Evaporative Emission Control System Pressure Sensor High Input Evaporative Emission System Purge Control Valve Circuit Low Fuel Level Sensor “A” Circuit Low Fuel Level Sensor “A” Circuit High Vehicle Speed Sensor “A” Starter Request Circuit Incorrect Immobilizer Key Internal Control Module Random Access Memory (RAM) Error Internal Control Module Read Only Memory (ROM) Error Throttle Control System Circuit Range/Performance Throttle Actuator Control Range/Performance (Bank 1) Transmission Control System (MIL Request) O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1) O2 Sensor Circuit Range/Performance (Low) (Bank 2 Sensor 1) O2 Sensor Circuit Range/Performance (High) (Bank 2 Sensor 1) Return Spring Failure Starter Switch Circuit Low Input Back-Up Voltage Circuit Malfunction Antenna Reference Code Incompatibility IMM Circuit Failure Key Communication Failure EGI Control Module EEPROM IMM Control Module EEPROM Meter Failure Intake Camshaft Position Actuator Control Circuit Low (Bank 1) Intake Camshaft Position Actuator Control Circuit High (Bank 1) Exhaust Camshaft Position Actuator Control Circuit Low (Bank 1) Exhaust Camshaft Position Actuator Control Circuit High (Bank 1) Intake Camshaft Position Actuator Control Circuit Low (Bank 2) Intake Camshaft Position Actuator Control Circuit High (Bank 2) Exhaust Camshaft Position Actuator Control Circuit Low (Bank 2) Exhaust Camshaft Position Actuator Control Circuit High (Bank 2) Throttle Actuator Control Motor Circuit Range/Performance Throttle Actuator Control Motor Circuit Low

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Condition — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

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Inspection Mode ENGINE (DIAGNOSTICS) DTC P2103 P2109 P2122 P2123 P2127 P2128 P2135 P2138 P2227 P2228 P2229 U0073 U0101 U0122 U0140 U0402 U0416 U0422

Item Throttle Actuator Control Motor Circuit High Throttle/Pedal Position Sensor “A” Minimum Stop Performance Throttle/Pedal Position Sensor/Switch “D” Circuit Low Input Throttle/Pedal Position Sensor/Switch “D” Circuit High Input Throttle/Pedal Position Sensor/Switch “E” Circuit Low Input Throttle/Pedal Position Sensor/Switch “E” Circuit High Input Throttle/Pedal Position Sensor/Switch “A”/“B” Voltage Correlation Throttle/Pedal Position Sensor/Switch “D”/“E” Voltage Correlation Atmospheric Pressure Sensor Range/Performance Barometric Pressure Circuit Low Barometric Pressure Circuit High CAN Failure, Bus ‘OFF’ Detection CAN (TCU) Data not Loaded CAN (VDC) Data not Loaded CAN (BCU) Data not Loaded CAN (TCU) Data Abnormal CAN (VDC) Data Abnormal CAN (BCU) Data Abnormal

Condition — — — — — — — — — — — — — — — — — —

1. PREPARATION FOR THE INSPECTION MODE 1) Check battery voltage is 12 V or more and fuel remains half [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8 Imp gal)]. 2) Lift up the vehicle using a garage jack and place it on rigid racks, or drive the vehicle onto free rollers. WARNING: • Before lifting up the vehicle, ensure parking brakes are applied. • Do not use a pantograph jack in place of a rigid rack. • Secure a rope or wire to the front or rear towing hooks to prevent the lateral runout of front wheels. • Before rotating the wheels, make sure that there is no one in front of the vehicle. Besides while the wheels are rotating, make sure that no one approaches the vehicle front side. • Make sure that there is nothing around the wheels. For AWD model, pay special attention to all four wheels. • While servicing, do not depress or release the clutch pedal or accelerator pedal quickly regardless of the engine speed. Quick operation may cause the vehicle to drop off the free roller. • To prevent the vehicle from slipping due to vibration, do not place anything between rigid rack and the vehicle.

(A)

(B)

(A) Rigid rack (B) Free roller

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EN-00041

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Inspection Mode ENGINE (DIAGNOSTICS)

2. SUBARU SELECT MONITOR 1) Check that no DTC remains after clearing memory. 2) Warm up the engine. 3) Prepare the Subaru Select Monitor kit.

CAUTION: Do not connect any scan tools except Subaru Select Monitor or general scan tool.

EN-07712

EN-05692

4) Prepare PC with Subaru Select Monitor installed. 5) Connect the USB cable to SDI (Subaru Diagnosis Interface) and USB port on the personal computer (dedicated port for the Subaru Select Monitor). NOTE: The dedicated port for the Subaru Select Monitor means the USB port which was used to install the Subaru Select Monitor. 6) Connect the diagnosis cable to SDI. 7) Install the delivery (test) mode fuse (A) of the main fuse box. (A)

EN-07556

8) Connect SDI to data link connector located in the lower portion of the instrument panel (on the driver’s side).

9) Start the PC. 10) Turn the ignition switch to ON (engine OFF) and run the “PC application for Subaru Select Monitor”. 11) On «Main Menu» display, select {Each System Check}. 12) On «System Selection Menu» display, select {Engine Control System}. 13) Click the [OK] button after the information of engine type has been displayed. 14) On «Engine Diagnosis» display, select {Dealer Check Mode Procedure}. 15) When the «Perform Inspection (Dealer Check) Mode?» is shown on the screen, click the [Next] button. 16) Perform subsequent procedures as instructed on the display screen. • If trouble still remains in the memory, the corresponding DTC appears on the display screen. NOTE: • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”. • Release the parking brake. • The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When engine control system diagnosis is finished, perform the VDC memory clearance procedure of self-diagnosis function.

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Inspection Mode ENGINE (DIAGNOSTICS)

3. GENERAL SCAN TOOL 1) Check that no DTC remains after clearing memory. 2) Warm up the engine. 3) Install the delivery (test) mode fuse (A) of the main fuse box.

• The speed difference between front and rear wheels may illuminate the ABS warning light, but this does not indicate a malfunction. When engine control system diagnosis is finished, perform the VDC memory clearance procedure of self-diagnosis function. 10) Using the general scan tool, check for DTC and record the result(s). NOTE: • For detailed operation procedures, refer to the general scan tool operation manual. • For details concerning DTC, refer to “List of Diagnostic Trouble Code (DTC)”.

(A)

EN-07556

4) Connect the general scan tool to data link connector located in the lower portion of the instrument panel (on the driver’s side). CAUTION: Do not connect any scan tools except Subaru Select Monitor or general scan tool.

EN-07712

5) Start the engine. NOTE: Make sure the select lever is placed in “P” position before starting. 6) Turn the neutral position switch to ON by operating select lever. 7) Depress the brake pedal to turn the brake switch ON. 8) Keep the engine speed in 2,500 — 3,000 rpm range for 40 seconds. 9) Place the select lever in “D” range and drive the vehicle at 5 to 10 km/h (3 to 6 MPH). NOTE: • For AWD model, release the parking brake.

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Drive Cycle ENGINE (DIAGNOSTICS)

12.Drive Cycle A: PROCEDURE It is necessary to perform the drive cycle listed below if DTC is not found in the Inspection Mode. It is possible to complete diagnosis of the DTC by performing the indicated drive cycle. After the repair for the DTC, perform a necessary drive cycle and make sure the function recovers and the DTC is recorded.

1. PREPARATION FOR DRIVE CYCLE 1) Check that the battery voltage is 12 V or more and fuel remains approx. half [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8 Imp gal)]. 2) After performing the diagnostics and Clear Memory Mode, check that no DTC remains. 3) Check the delivery (test) mode fuse is removed. NOTE: • Perform the drive cycle after warming up the engine except when the engine coolant temperature at engine start is specified. • Perform the drive cycle twice if the DTC in the list is marked with *. After completing the first drive cycle, stop the engine and perform second diagnosis in same condition.

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Drive Cycle ENGINE (DIAGNOSTICS)

2. DRIVE CYCLE A DTC

Item

*P0125

Insufficient Coolant Temperature for Closed Loop Fuel Control

*P0126

Insufficient Engine Coolant Temperature for Stable Operation Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature)

*P0128

Condition Engine coolant temperature at engine start is less than 20°C (68°F). — —

*P0133 *P0141 *P0153 *P0161

O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) O2 Sensor Heater Circuit (Bank1 Sensor2) O2 Sensor Circuit Slow Response (Bank 2 Sensor 1) O2 Sensor Heater Circuit (Bank2 Sensor2)

— — — — Complete diagnosis with drive cycle B or C as well.

*P0171

System Too Lean (Bank 1)

*P0172

System Too Rich (Bank 1)

Complete diagnosis with drive cycle B or C as well.

*P0174

System Too Lean (Bank 2)

Complete diagnosis with drive cycle B or C as well.

*P0175

System Too Rich (Bank 2)

*P0196

Engine Oil Temperature Sensor Circuit Range/Performance

*P0301

Cylinder 1 Misfire Detected

*P0302

Cylinder 2 Misfire Detected

*P0303

Cylinder 3 Misfire Detected

*P0304

Cylinder 4 Misfire Detected

*P0305

Cylinder 5 Misfire Detected

*P0306

Cylinder 6 Misfire Detected

*P0420

Catalyst System Efficiency Below Threshold (Bank 1)

*P0442

Evaporative Emission Control System Leak Detected (Small Leak)

*P0451

Evaporative Emission Control System Pressure Sensor

*P0456

Evaporative Emission Control System Leak Detected (Very Small Leak)

*P0457

Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off)

*P0464 P1443

Fuel Level Sensor Circuit Intermittent Vent Control Solenoid Valve Function Problem

*P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

Complete diagnosis with drive cycle B or C as well.

*P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

Complete diagnosis with drive cycle B or C as well.

*P2098

Post Catalyst Fuel Trim System Too Lean (Bank 2)

*P2099

Post Catalyst Fuel Trim System Too Rich (Bank 2)

Complete diagnosis with drive cycle B or C as well. — Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well.

Diagnostic procedure: 1) Drive for 20 minutes at a constant speed of 80 km/h (50 MPH). 2) Stop the vehicle and idle for one minute.

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Complete diagnosis with drive cycle B or C as well. — Engine coolant temperature at engine start is less than 25°C (77°F). — Engine coolant temperature at engine start is less than 25°C (77°F). Engine coolant temperature at engine start is less than 25°C (77°F). — —

Complete diagnosis with drive cycle B or C as well. Complete diagnosis with drive cycle B or C as well.

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Drive Cycle ENGINE (DIAGNOSTICS)

3. DRIVE CYCLE B DTC

Item

Condition Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well.

*P0171

System Too Lean (Bank 1)

*P0172

System Too Rich (Bank 1)

*P0174

System Too Lean (Bank 2)

*P0175

System Too Rich (Bank 2)

Complete diagnosis with drive cycle A or C as well.

*P0301

Cylinder 1 Misfire Detected

Complete diagnosis with drive cycle A or C as well.

*P0302

Cylinder 2 Misfire Detected

Complete diagnosis with drive cycle A or C as well.

*P0303

Cylinder 3 Misfire Detected

Complete diagnosis with drive cycle A or C as well.

*P0304

Cylinder 4 Misfire Detected

*P0305

Cylinder 5 Misfire Detected

*P0306

Cylinder 6 Misfire Detected

*P0459 *P0506 *P0507

Evaporative Emission System Purge Control Valve Circuit High Idle Air Control System RPM Lower Than Expected Idle Air Control System RPM Higher Than Expected

*P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

Complete diagnosis with drive cycle A or C as well.

*P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

Complete diagnosis with drive cycle A or C as well.

*P2098

Post Catalyst Fuel Trim System Too Lean (Bank 2)

Complete diagnosis with drive cycle A or C as well.

*P2099

Post Catalyst Fuel Trim System Too Rich (Bank 2)

Complete diagnosis with drive cycle A or C as well.

Complete diagnosis with drive cycle A or C as well. Complete diagnosis with drive cycle A or C as well.

Diagnostic procedure: 1) Drive at 10 km/h (6 MPH) or more. 2) Stop the vehicle and idle for ten minutes.

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Complete diagnosis with drive cycle A or C as well. — — —

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Drive Cycle ENGINE (DIAGNOSTICS)

4. DRIVE CYCLE C DTC *P0030 *P0050 *P0068 *P0101 P0134 *P0139 P0154 *P0159

Item HO2S Heater Control Circuit (Bank 1 Sensor 1) HO2S Heater Control Circuit (Bank 2 Sensor 1) MAP/MAF - Throttle Position Correlation Mass or Volume Air Flow Circuit Range/Performance O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 1) O2 Sensor Circuit Slow Response (Bank 2 Sensor 2)

Condition — — — — — — — —

*P0171

System Too Lean (Bank 1)

*P0172

System Too Rich (Bank 1)

*P0174

System Too Lean (Bank 2)

*P0175

System Too Rich (Bank 2)

Complete diagnosis with drive cycle A or B as well.

*P0301

Cylinder 1 Misfire Detected

Complete diagnosis with drive cycle A or B as well.

*P0302

Cylinder 2 Misfire Detected

Complete diagnosis with drive cycle A or B as well.

*P0303

Cylinder 3 Misfire Detected

*P0304

Cylinder 4 Misfire Detected

*P0305

Cylinder 5 Misfire Detected

*P0306

Cylinder 6 Misfire Detected

*P0400 P1492 P1493 P1494 P1495 P1496 P1497 P1498 P1499

Exhaust Gas Recirculation Flow EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input) EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input)

*P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

Complete diagnosis with drive cycle A or B as well.

*P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

Complete diagnosis with drive cycle A or B as well.

*P2098

Post Catalyst Fuel Trim System Too Lean (Bank 2)

Complete diagnosis with drive cycle A or B as well.

*P2099

Post Catalyst Fuel Trim System Too Rich (Bank 2)

Complete diagnosis with drive cycle A or B as well.

Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well.

Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well. Complete diagnosis with drive cycle A or B as well.

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Complete diagnosis with drive cycle A or B as well. — — — — — — — — —

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Drive Cycle ENGINE (DIAGNOSTICS)

Diagnostic procedure: Drive according to the drive pattern described below. (H)

(C)

97 (60)

(D) 64 (40)

(G)

(F)

(E)

(B)

(A) 0

50

100

(I)

150

EN-00842

(A) (B) (C)

Idle the engine for 10 seconds or more. Accelerate the vehicle to 97 km/h (60 MPH) within 20 seconds. Drive the vehicle at 97 km/h (60 MPH) for 20 seconds.

(D) (E) (F)

Decelerate the vehicle to 64 km/h (40 MPH) with throttle fully closed. Drive the vehicle at 64 km/h (40 MPH) for 20 seconds. Accelerate the vehicle to 97 km/h (60 MPH) within 10 seconds.

(G) (H)

Stop the vehicle with throttle fully closed. Vehicle speed km/h (MPH)

(I)

Sec.

5. DRIVE CYCLE D DTC *P0181

Item Fuel Temperature Sensor “A” Circuit Range/Performance

Condition —

NOTE: In drive cycle D, one drive cycle will be established when both the drift diagnosis and stuck diagnosis have completed. Diagnostic procedure: DRIFT DIAGNOSIS 1) Make sure of the items below before starting the engine. • Engine coolant temperature is less than 30°C (86°F). • Remaining fuel is 10 2 (2.6 US gal, 2.2 Imp gal) or more. • Battery voltage is 10.9 V or more. 2) Idle the engine until engine coolant temperature is at least 10°C (18°F) higher than it was when engine started. 3) After the engine has reached the state of procedure 2), idle the engine for another 5 minutes or more. STUCK DIAGNOSIS 1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. 3) Drive the vehicle for the distance equal to the fuel of 50 2 (13.2 US gal, 11 Imp gal). NOTE: • It is acceptable to drive the vehicle intermittently. • Do not disconnect the battery terminals during stuck diagnosis. (Data will be cleared by disconnecting the battery terminals.)

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Drive Cycle ENGINE (DIAGNOSTICS)

6. DRIVE CYCLE E DTC *P0461

Item Fuel Level Sensor “A” Circuit Range/Performance

Condition —

Diagnostic procedure: 1) Make sure that the battery voltage is 10.9 V or more. 2) Perform the Clear Memory Mode. 3) Drive the vehicle for the distance equal to the fuel of 30 2 (7.9 US gal, 6.6 Imp gal). NOTE: • It is acceptable to drive the vehicle intermittently. • Do not disconnect the battery terminals while diagnosing. (Data will be cleared by disconnecting the battery terminals.)

7. DRIVE CYCLE F DTC *P0111

Item Intake Air Temperature Sensor 1 Circuit Range/Performance

Condition —

Diagnostic procedure: 1) Make sure that the engine coolant temperature is less than 30°C (86°F). 2) Drive according to the drive pattern described below. (A)

(2)

(4)

(6)

80 km/h (50 MPH)

0

(3)

(5)

(7)

(B)

(1) EN-07588

(A)

Vehicle speed

(B)

Elapsed time

(1)

Idle the engine for 10 seconds after engine start. Drive for 8 minutes at a constant speed of 80 km/h (50 MPH). Stop the vehicle and idle for 30 seconds.

(4)

Drive for 30 seconds at a constant speed of 80 km/h (50 MPH). Stop the vehicle and idle for 30 seconds.

(2) (3)

(5)

(6) (7)

Drive for 30 seconds at a constant speed of 80 km/h (50 MPH). Stop the vehicle and idle for 30 seconds.

NOTE: • There is no given transition time between idling and cruising. • Driving at constant speed only on a downhill causes smaller engine load and may result in failure to obtain a right diagnostic result. • When the engine stops while performing drive cycle F, perform it again from the state of procedure 1).

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Drive Cycle ENGINE (DIAGNOSTICS)

8. DRIVE CYCLE H DTC *P1602

Item Control Module Programming Error

Condition —

Diagnostic procedure: 1) Perform the Clear Memory Mode. 2) With the ignition switch ON (engine OFF), read the engine coolant temperature, intake air temperature and fuel temperature. 3) If the values from step 2) satisfy the following two conditions, idle the engine for one minute.

Condition: | Engine coolant temperature — Intake air temperature | ≤ 5°C (41°F) | Engine coolant temperature — Fuel temperature | ≤ 2°C (36°F) NOTE: • If the conditions are not satisfied, turn the ignition switch to OFF and wait until the parameters are satisfied. • Hold the select lever in “P” range or “N” range at idling.

EN(H6DO)(diag)-56

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Clear Memory Mode ENGINE (DIAGNOSTICS)

13.Clear Memory Mode A: OPERATION 1. SUBARU SELECT MONITOR NOTE: • Initial diagnosis of electronic throttle control is performed after memory clearance. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine. • For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

2. GENERAL SCAN TOOL For procedures clearing memory using the general scan tool, refer to the general scan tool operation manual. NOTE: Initial diagnosis of electronic throttle control is performed after memory clearance. For this reason, start the engine after 10 seconds or more have elapsed since the ignition switch was turned to ON.

EN(H6DO)(diag)-57

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System Operation Check Mode ENGINE (DIAGNOSTICS)

14.System Operation Check Mode A: OPERATION CAUTION: After executing the system operation check mode, execute the Clear Memory Mode. NOTE: For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

EN(H6DO)(diag)-58

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

15.Malfunction Indicator Light A: PROCEDURE 1. Activation of malfunction indicator light. ↓ 2. Malfunction indicator light does not come on. ↓ 3. Malfunction indicator light does not go off. ↓ 4. Malfunction indicator light does not blink. ↓ 5. Malfunction indicator light remains blinking.

EN(H6DO)(diag)-59

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

B: ACTIVATION OF MALFUNCTION INDICATOR LIGHT 1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light (A) in the combination meter illuminates. NOTE: If the malfunction indicator light does not illuminate, perform diagnostics of the malfunction indicator light circuit or the combination meter circuit.

3) If the diagnostic system detects a misfire which could damage the catalyst, the malfunction indicator light will blink at a cycle of 1 Hz. (1) (2) (3) (4) (6) (5) EN-01680

(1) (2) (3) (4) (5) (6)

CHECK ENGINE

CHECK ENGINE

(A) EN-07714

ON OFF Ignition switch ON Engine start Misfire start 1 second

4) Install the delivery (test) mode fuse (A) with ignition switch to OFF.

2) After starting the engine, the malfunction indicator light goes out. If it does not go off, any of the engine and emission control system has malfunction.

(A)

(1) (3) (4) (2) (3) (4)

EN-07556 (5) (6)

(1) (2) (3) (4) (5) (6)

No faulty Trouble occurs ON OFF Ignition switch ON Engine start

EN-01679

(1) When the ignition switch is turned to ON (engine OFF), the malfunction indicator light illuminates. (2) After the engine starts, malfunction indicator light blinks in a cycle of 0.5 Hz. (During diagnosis)

EN(H6DO)(diag)-60

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

(3) Malfunction indicator light blinks at a cycle of 3 Hz after diagnosis if there is no trouble. Malfunction indicator light illuminates if faulty. (1) (2) (4)

(3)

EN-01681

(1) (2) (3) (4)

ON OFF Ignition switch ON 1 second

EN(H6DO)(diag)-61

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON DIAGNOSIS: The malfunction indicator light circuit is open or shorted. TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), malfunction indicator light does not illuminate. WIRING DIAGRAM:

B72

IGNITION SWITCH

BATTERY

F/B No. 5

SBF-5 1

MAIN SBF

3

COMBINATION METER i10 19 6

E DELIVERY (TEST) MODE FUSE M/B No. 36

B138

18

i3

* *

B : B135

B138 1 2 3 4 5 6 7 8

C : B136

*

ECM

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

: TERMINAL No. OPTIONAL ARRANGEMENT

C : B136

B : B135

B72 1 2 3 4 5 6

J/C

C4

C34

B33

B38

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 6 14 15 16 25 26 27 33 34 35

i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

EN-07763

1

Step Check Is the voltage 10 V or more? CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 33 (+) — Chassis ground (–):

EN(H6DO)(diag)-62

Yes Go to step 5.

No Go to step 2.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

2

3

4

5

6

Step Check Yes CHECK HARNESS BETWEEN COMBINAIs the resistance less than 1 Ω? Go to step 3. TION METER AND ECM CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the combination meter. 3) Disconnect the connector from ECM and combination meter. 4) Measure the resistance of harness between ECM connector and combination meter connector. Connector & terminal (B135) No. 33 — (i10) No. 6: CHECK FOR POOR CONTACT. Check for poor contact of combination meter connector.

Is there poor contact of combi- Repair the poor nation meter connector? contact of combination meter connector. CHECK HARNESS BETWEEN COMBINAIs the voltage 10 V or more? Replace the meter TION METER AND IGNITION SWITCH CONcase assembly of NECTOR. combination meter. 1) Turn the ignition switch to ON.

Connector & terminal (i10) No. 19 (+) — Chassis ground (–):

CHECK FOR POOR CONTACT. Check for poor connection by shaking or pulling ECM connector and harness. CHECK ECM CONNECTOR. Check the connection of ECM connector.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and combination meter connector • Poor contact of coupling connector Go to step 4.

Check the following item and repair if necessary. NOTE: • Blown-out of fuse (F/B No. 5) • Open harness of the power supply circuit or defective grounding Go to step 6.

Does the malfunction indicator Repair the poor light illuminate? contact of ECM connector. Is the ECM connector correctly Replace the ECM. Repair the connecconnected?

EN(H6DO)(diag)-63

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF DIAGNOSIS: The malfunction indicator light circuit is shorted. TROUBLE SYMPTOM: Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select Monitor or general scan tool display. WIRING DIAGRAM:

B72

IGNITION SWITCH

BATTERY

F/B No. 5

SBF-5 1

MAIN SBF

3

COMBINATION METER i10 19 6

E DELIVERY (TEST) MODE FUSE M/B No. 36

B138

18

i3

* *

B : B135

C : B136

B72 1 2 3 4 5 6

B138

J/C

C4

C34

B33

B38

*

ECM

C : B136

B : B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

: TERMINAL No. OPTIONAL ARRANGEMENT

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 6 14 15 16 25 26 27 33 34 35

i10

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

EN-07763

1

Step CHECK HARNESS BETWEEN COMBINATION METER AND ECM CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Turn the ignition switch to ON.

Check Yes Does the malfunction indicator Repair the ground light illuminate? short circuit of harness between combination meter and ECM connector.

EN(H6DO)(diag)-64

No Replace the ECM.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK DIAGNOSIS: • The malfunction indicator light circuit is open or shorted. • The delivery (test) mode fuse circuit is open. TROUBLE SYMPTOM: Malfunction indicator light does not blink during Inspection Mode. WIRING DIAGRAM:

B72

IGNITION SWITCH

BATTERY

F/B No. 5

SBF-5 1

MAIN SBF

3

COMBINATION METER i10 19 6

E DELIVERY (TEST) MODE FUSE M/B No. 36

B138

18

i3

* *

B : B135

B72 1 2 3 4 5 6

B138 1 2 3 4 5 6 7 8

J/C

C4

C34

B33

B38

C : B136

*

ECM

C : B136

B : B135 B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

: TERMINAL No. OPTIONAL ARRANGEMENT

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 6 14 15 16 25 26 27 33 34 35

i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

EN-07763

EN(H6DO)(diag)-65

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator Go to step 2. CATOR LIGHT. light illuminate? 1) Turn the ignition switch to OFF. 2) Check the delivery (test) mode fuse is removed. 3) Turn the ignition switch to ON. (engine OFF)

No Repair the malfunction indicator light circuit. CHECK HARNESS BETWEEN COMBINADoes the malfunction indicator Repair the ground Go to step 3. TION METER AND ECM CONNECTOR. light illuminate? short circuit of har1) Turn the ignition switch to OFF. ness between 2) Disconnect the connector from ECM. combination meter 3) Turn the ignition switch to ON. and ECM connector. CHECK HARNESS BETWEEN ECM AND DE- Is the resistance less than 1 Ω? Go to step 4. Repair the harness LIVERY (TEST) MODE FUSE. and connector. 1) Turn the ignition switch to OFF. NOTE: 2) Install the delivery (test) mode fuse of the In this case, repair main fuse box. the following item: 3) Measure the resistance of harness between • Open circuit of ECM connectors. harness between Connector & terminal ECM and delivery (B136) No. 4 — (B136) No. 34: (test) mode fuse • Poor contact of joint connector CHECK FOR POOR CONTACT. Is there poor contact of ECM Repair the poor Replace the ECM. Check for poor contact of ECM connector. connector? contact of ECM

EN(H6DO)(diag)-66

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING DIAGNOSIS: The delivery (test) mode fuse circuit is shorted. TROUBLE SYMPTOM: Malfunction indicator light blinks when delivery (test) mode fuse is not connected. WIRING DIAGRAM:

B72

IGNITION SWITCH

BATTERY

F/B No. 5

SBF-5 1

MAIN SBF

3

COMBINATION METER i10 19 6

E DELIVERY (TEST) MODE FUSE M/B No. 36

B138

18

i3

* *

B : B135

C : B136

B138

*

ECM

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

: TERMINAL No. OPTIONAL ARRANGEMENT

C : B136

B : B135

B72 1 2 3 4 5 6

J/C

C4

C34

B33

B38

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

5 6 14 15 16 25 26 27 33 34 35

i10

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

EN-07763

1

Step CHECK DELIVERY (TEST) MODE FUSE. 1) Check the delivery (test) mode fuse is removed. 2) Turn the ignition switch to ON.

Check Yes Does the malfunction indicator Go to step 2. light blink?

EN(H6DO)(diag)-67

No System is normal. NOTE: Malfunction indicator light blinks when delivery (test) mode fuse is connected.

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Malfunction Indicator Light ENGINE (DIAGNOSTICS)

2

Step Check CHECK HARNESS BETWEEN ECM CONIs the resistance less than 5 Ω? NECTOR AND CHASSIS GROUND TERMINAL. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM connector and chassis ground. Connector & terminal (B136) No. 34 — Chassis ground:

EN(H6DO)(diag)-68

Yes Repair the short circuit to ground in harness between ECM and delivery (test) mode fuse.

No Replace the ECM.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

16.Diagnostics for Engine Starting Failure A: PROCEDURE 1. Check of the fuel amount ↓ 2. Inspection of starter motor circuit. ↓ 3. Inspection of ECM power supply and ground line. ↓ 4. Inspection of ignition control system. ↓ 5. Inspection of fuel pump circuit. ↓ 6. Inspection of fuel injector circuit.

EN(H6DO)(diag)-69

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

B: STARTER MOTOR CIRCUIT CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

6

BATTERY SBF-5

MAIN SBF

3

2 IGNITION SWITCH

B72

E

4

2

4

2

F/B No. 21

B498

3

1

STARTER RELAY

3

1

INHIBITOR RELAY

B14

B54 TCM

STARTER MOTOR

B493

C16

B26

C35

11

ECM B : B135

C : B136

B54 B493

B498

1 2 3 4

B72 1 2 3 4 5 6

B : B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07764

1 2

Step Check CHECK BATTERY. Is the voltage 12 V or more? Check the battery voltage. CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate?

EN(H6DO)(diag)-70

Yes Go to step 2. Go to step 3.

No Charge or replace the battery. Go to step 4.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS) Step 3

CHECK DTC.

4

CHECK INPUT SIGNAL FOR STARTER MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from starter motor. 3) Place the select lever in “P” range or “N” range. 4) Turn the ignition switch to START. 5) Measure the voltage between the starter motor connector and the engine ground. Connector & terminal (B14) No. 1 (+) — Engine ground (–): CHECK INPUT SIGNAL FOR STARTER MOTOR. 1) Place the select lever in “P” range or “N” range. 2) Turn the ignition switch to START. 3) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B493) No. 3 (+) — Chassis ground (–): CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ignition switch. 3) Measure the voltage between ignition switch connector and chassis ground. Connector & terminal (B72) No. 3 (+) — Chassis ground (–): CHECK IGNITION SWITCH. Measure the resistance between ignition switch terminals after turning the ignition switch to START position. Terminals No. 3 — No. 2: No. 3 — No. 6:

5

6

7

Check Is DTC displayed?

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Is the voltage 10 V or more?

Check the starter motor.

Is the voltage 10 V or more?

Repair the open circuit of the harness between starter relay connector and starter motor.

Go to step 6.

Is the voltage 10 V or more?

Go to step 7.

Repair the power supply circuit.

Is the resistance less than 1 Ω? Go to step 8.

EN(H6DO)(diag)-71

No The circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 5.

Replace the ignition switch.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

8

9

10

11

12

13

Step CHECK INPUT VOLTAGE OF STARTER RELAY. 1) Remove the starter relay. 2) Connect the connector to ignition switch. 3) Turn the ignition switch to START. 4) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B493) No. 4 (+) — Chassis ground (–): CHECK STARTER RELAY. 1) Connect the battery to starter relay terminals No. 1 and No. 2. 2) Measure the resistance between starter relay terminals. Terminals No. 3 — No. 4: CHECK HARNESS BETWEEN ECM AND STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and starter relay connector. Connector & terminal (B135) No. 26 — (B493) No. 1: (B136) No. 16 — (B493) No. 3: CHECK INPUT VOLTAGE OF STARTER RELAY. 1) Connect the connector to ECM. 2) Place the select lever in “P” range or “N” range. 3) Turn the ignition switch to START. 4) Measure the voltage between starter relay connector and chassis ground. Connector & terminal (B493) No. 2 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND INHIBITOR RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the inhibitor relay connector. 3) Measure the resistance of harness between ECM and inhibitor relay connector. Connector & terminal (B136) No. 35 — (B498) No. 1:

Check Is the voltage 10 V or more?

Yes Go to step 9.

No Repair the open circuit of harness between starter relay connector and ignition switch connector.

Is the resistance less than 1 Ω? Go to step 10.

Replace the starter relay.

Is the resistance less than 1 Ω? Go to step 11.

Repair the open circuit of harness between ECM and starter relay connector.

Is the voltage 10 V or more?

Go to step 12.

Is the resistance less than 1 Ω? Check the ECM power supply and ground line. CHECK INPUT VOLTAGE OF INHIBITOR RE- Is the voltage 10 V or more? Go to step 14. LAY. 1) Turn the ignition switch to OFF. 2) Disconnect the inhibitor relay connector. 3) Turn the ignition switch to START. 4) Measure the voltage between inhibitor relay connector and chassis ground. Connector & terminal (B498) No. 2 (+) — Chassis ground (–): (B498) No. 4 (+) — Chassis ground (–):

EN(H6DO)(diag)-72

Go to step 13.

Repair the open circuit of harness between ECM and inhibitor relay connector.

Check the following item and repair if necessary. • Blown-out of fuse (F/B No. 21) • Open or ground short circuit of harness between ignition switch connector and inhibitor relay connector

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

14

15

Step Check CHECK INHIBITOR RELAY. Is the resistance less than 1 Ω? 1) Connect the battery to inhibitor relay terminals No. 1 and No. 2. 2) Measure the resistance between inhibitor relay terminals. Terminals No. 3 — No. 4: CHECK HARNESS BETWEEN INHIBITOR Is the resistance less than 1 Ω? RELAY CONNECTOR AND STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between inhibitor relay connector and starter relay connector. Connector & terminal (B498) No. 3 — (B493) No. 2:

EN(H6DO)(diag)-73

Yes Go to step 15.

No Replace the inhibitor relay.

Repair the open circuit of harness between TCM and inhibitor relay connector.

Repair the open circuit of harness between inhibitor relay connector and starter relay connector.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM) CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

B220

M/B No. 16

4 3 M/B No. 12 1 2 B72

IGNITION SWITCH

F/B No. 12

SBF-5

MAIN SBF

3

C2 C30

B13 C1 D7

1

A : B134 B : B135 ECM C : B136 BATTERY

A3 D5 D3 D1 A4 A6

D : B137

35 37 34 40 36

B21 E2

E

E

A : B134

B : B135

B72 1 2 8 9 10 18 19 20 28 29 30

1 2 3 4 5 6

C : B136

B220

1 3 4 2

5 7 8 6

9 11 12 10

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07765

1

Step Check Yes CHECK MAIN RELAY. Is the resistance less than 1 Ω? Go to step 2. 1) Turn the ignition switch to OFF. 2) Remove the main relay. 3) Connect the battery to main relay terminals No. 1 and No. 2. 4) Measure the resistance between main relay terminals. Terminals No. 3 — No. 4:

EN(H6DO)(diag)-74

No Replace the main relay.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

2

3

4

5

6

Step Check Yes CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? Go to step 3. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM connector and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground: CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 2 (+) — Chassis ground (–): (B136) No. 30 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF MAIN RELAY. Measure the voltage between main relay connector and chassis ground. Connector & terminal (B220) No. 1 (+) — Chassis ground (–): (B220) No. 4 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to OFF. 2) Install the main relay. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 13 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF ECM. 1) Turn the ignition switch to OFF. 2) Connect the connector to ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 1 (+) — Chassis ground (–): (B137) No. 7 (+) — Chassis ground (–):

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM connector and engine ground terminal. • Poor contact of coupling connector Repair the open or ground short circuit of harness of power supply circuit.

Is the voltage 10 V or more?

Go to step 4.

Is the voltage 10 V or more?

Go to step 5.

Repair the open or ground short circuit of harness of power supply circuit.

Is the voltage 10 V or more?

Go to step 6.

Repair the open circuit of harness between ECM connector and main relay connector.

Is the voltage 10 V or more?

Check ignition control system.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM connector and fuel injector connector • Poor contact of main relay connector • Poor contact of ECM connector

EN(H6DO)(diag)-75

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

D: IGNITION CONTROL SYSTEM CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: B220 IG RELAY M/B No. 14 7

8

26

25

32

31

22

21

ECM

B134

44

50

10

31

20

9

49

B21

E46

2

1

E45

3

2

1

E34

3

2

1

E33

3

2

1

E32

3

2

1

E31

3

2

1

3

E2

E IGNITION COIL No. 1

E31

E32

E33

E34

E45

E46

IGNITION COIL No. 2

IGNITION COIL No. 4

IGNITION COIL No. 5

E

IGNITION COIL No. 6

B21 B220

1 3 4 2 1 2 3

IGNITION COIL No. 3

5 7 8 6

9 11 12 10

B134

13 15 16 14

17 18 20 21 19

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07766

1

Step Check Yes CHECK SPARK PLUG CONDITION. Is the spark plug condition nor- Go to step 2. 1) Remove the spark plug. 2) Check the spark plug condition.

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No Replace the spark plug.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

2

3

4

5

6

Step Check CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cylin1) Connect the spark plug to ignition coil. der? 2) Release the fuel pressure. 3) Contact the spark plug thread portion to engine. 4) While opening the throttle valve fully, start the engine to check if spark occurs at each cylinder. CHECK IGNITION COIL POWER SUPPLY Is the voltage 10 V or more? CIRCUIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ignition coil. 3) Turn the ignition switch to ON. 4) Measure the voltage between ignition coil connector and engine ground. Connector & terminal (E31) No. 3 (+) — Engine ground (–): (E32) No. 3 (+) — Engine ground (–): (E33) No. 3 (+) — Engine ground (–): (E34) No. 3 (+) — Engine ground (–): (E45) No. 3 (+) — Engine ground (–): (E46) No. 3 (+) — Engine ground (–):

Yes No Check fuel pump Go to step 3. system.

Go to step 4.

CHECK HARNESS OF IGNITION COIL Is the resistance less than 5 Ω? Go to step 5. GROUND CIRCUIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between ignition coil connector and engine ground. Connector & terminal (E31) No. 2 — Engine ground: (E32) No. 2 — Engine ground: (E33) No. 2 — Engine ground: (E34) No. 2 — Engine ground: (E45) No. 2 — Engine ground: (E46) No. 2 — Engine ground CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Ω? Go to step 6. NITION COIL CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and ignition coil connector. Connector & terminal (B134) No. 21 — (E31) No. 1: (B134) No. 22 — (E32) No. 1: (B134) No. 31 — (E33) No. 1: (B134) No. 32 — (E34) No. 1: (B134) No. 25 — (E45) No. 1: (B134) No. 26 — (E46) No. 1: CHECK HARNESS BETWEEN ECM AND IG- Is the resistance 1 MΩ or NITION COIL CONNECTOR. more? Measure the resistance of harness between ECM connector and chassis ground. Connector & terminal: (B134) No. 21 — Chassis ground: (B134) No. 22 — Chassis ground: (B134) No. 31 — Chassis ground: (B134) No. 32 — Chassis ground: (B134) No. 25 — Chassis ground: (B134) No. 26 — Chassis ground:

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Go to step 7.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in harness of power supply circuit • Blown out of fuse (M/B No. 14) • Poor contact of coupling connector Repair the open circuit in harness between ignition coil connector and engine grounding terminal.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM connector and the ignition coil connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM connector and ignition coil connector.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

7

Step CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is there poor contact of ECM connector?

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Yes Repair the poor contact of ECM connector.

No Replace the ignition coil.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

E: FUEL PUMP CIRCUIT CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B220 FUEL PUMP RELAY R333

R122

FUEL PUMP CU

i155

i3

M/B No. 20

14 10 4

2 4 1

8 6 7 9 10 5

BATTERY

B38 20

21

ECM C33 B10

B : B135 C : B136

FUEL PUMP R15

R58

R57 1

5

2

6

M

E

E

i155

R58 R122 1 2

1 3

3 4 1 2 5 6 7 8 9 10

3 4

R57

2 4 5 6 7 8 9 10 11

5 6 B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135 13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07767

1

Step Check CHECK OPERATING SOUND OF FUEL Does the fuel pump emit operPUMP. ating sound? Make sure that the fuel pump operates for two seconds when turning the ignition switch to ON. NOTE: Fuel pump operation can be executed using the Subaru Select Monitor. For detailed procedures, refer to “System Operation Check”.

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Yes Check the fuel injector circuit.

No Display the DTC.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

F: FUEL INJECTOR CIRCUIT CAUTION: • Check or repair only faulty parts. • After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2

24

23

13

12

11

10

ECM

B134

46

47

51

52

53

54

48

B21

FUEL INJECTOR No. 4

FUEL INJECTOR No. 6

FUEL INJECTOR No. 5

B220

E17

E43

E44

1 2

E

B21

E16

E6

E44

1

E43

2

1

E17

2

1

E6

2

1

2

FUEL INJECTOR No. 3

FUEL INJECTOR No. 2

FUEL INJECTOR No. 1

E5

E16

1

E5

2

1

2

E2

1 3 4 2

5 7 8 6

9 11 12 10

B134

13 15 16 14

17 18 20 21 19

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07768

1

Step Check CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump emit operTOR. ating sound? While cranking the engine, check each fuel injector emits operating sound. Use a sound scope or listen by attaching a screwdriver to the injector for this check.

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Yes No Check the fuel Go to step 2. pressure.

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Diagnostics for Engine Starting Failure ENGINE (DIAGNOSTICS)

2

3

4

5

6

Step Check CHECK POWER SUPPLY TO EACH FUEL IN- Is the voltage 10 V or more? JECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector. 3) Turn the ignition switch to ON. 4) Measure the voltage between fuel injector connector and the engine ground. Connector & terminal #1 (E5) No. 2 (+) — Engine ground (–): #2 (E16) No. 2 (+) — Engine ground (–): #3 (E6) No. 2 (+) — Engine ground (–): #4 (E17) No. 2 (+) — Engine ground (–): #5 (E43) No. 2 (+) — Engine ground (–): #6 (E44) No. 2 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and fuel injector connector. Connector & terminal #1 (B134) No. 10 — (E5) No. 1: #2 (B134) No. 11 — (E16) No. 1: #3 (B134) No. 12 — (E6) No. 1: #4 (B134) No. 13 — (E17) No. 1: #5 (B134) No. 23 — (E43) No. 1: #6 (B134) No. 24 — (E44) No. 1: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal #1 (B134) No. 10 — Chassis ground: #2 (B134) No. 11 — Chassis ground: #3 (B134) No. 12 — Chassis ground: #4 (B134) No. 13 — Chassis ground: #5 (B134) No. 23 — Chassis ground: #6 (B134) No. 24 — Chassis ground: CHECK EACH FUEL INJECTOR. Measure the resistance between each fuel injector terminals. Terminals No. 1 — No. 2: CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Yes Go to step 3.

Is the resistance less than 1 Ω? Go to step 4.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between main relay and fuel injector connector • Poor contact of main relay connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel injector connector • Poor contact of coupling connector

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the ground short circuit of harness between ECM and fuel injector connector.

Is the resistance 5 — 20 Ω?

Go to step 6.

Replace the faulty fuel injector.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

Inspection using “General Diagnostic Table”.

EN(H6DO)(diag)-81

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

17.List of Diagnostic Trouble Code (DTC) A: LIST DTC P0011

P0014

Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Exhaust AVCS System 1 (Range/ Performance)

P0016

Crankshaft Position - Camshaft Position Correlation (Bank1)

P0017

Crank and Cam Timing B System Failure (Bank 1)

P0018

Crankshaft Position - Camshaft Position Correlation (Bank2)

P0019

Crank and Cam Timing B System Failure (Bank 2)

P0021

Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 2) Exhaust AVCS System 2 (Range/ Performance)

P0024

P0030

HO2S Heater Control Circuit (Bank 1 Sensor 1)

P0031

HO2S Heater Control Circuit Low (Bank 1 Sensor 1)

P0032

HO2S Heater Control Circuit High (Bank 1 Sensor 1)

P0037

HO2S Heater Control Circuit Low (Bank 1 Sensor 2)

P0038

HO2S Heater Control Circuit High (Bank 1 Sensor 2)

P0050

HO2S Heater Control Circuit (Bank 2 Sensor 1)

P0051

HO2S Heater Control Circuit Low (Bank 2 Sensor 1)

P0052

HO2S Heater Control Circuit High (Bank 2 Sensor 1)

P0057

HO2S Heater Control Circuit Low (Bank 2 Sensor 2)

Index











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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0058

P0068

P0101

P0102

P0103

P0107

P0108

P0111

P0112

P0113

P0117

P0118

P0122

P0123

P0125

P0126

P0128

P0131

Item HO2S Heater Control Circuit High (Bank 2 Sensor 2)

Index

MAP/MAF - Throttle Position Correla- Mass or Volume Air Flow Circuit

Mass or Volume Air Flow Circuit Low Mass or Volume Air Flow Circuit High Manifold Absolute Pressure/Baro Manifold Absolute Pressure/Baro Intake Air Temperature Sensor 1 Cir- Intake Air Temperature Sensor 1 Cir- Intake Air Temperature Sensor 1 Cir- Engine Coolant Temperature Circuit Engine Coolant Temperature Circuit Throttle/Pedal Position Sensor/ Switch “A” Circuit Low

Throttle/Pedal Position Sensor/

Insufficient Coolant Temperature for

Insufficient Engine Coolant Tempera- Coolant Thermostat (Engine Coolant O2 Sensor Circuit Low Voltage (Bank

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0132

Item O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)

P0133

O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)

P0134

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)

P0137

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)

P0138

O2 Sensor Circuit High Voltage (Bank 1 Sensor 2)

P0139

O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)

P0140

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)

P0141

O2 Sensor Heater Circuit (Bank1 Sensor2)

P0151

O2 Sensor Circuit Low Voltage (Bank 2 Sensor 1)

P0152

O2 Sensor Circuit High Voltage (Bank 2 Sensor 1)

P0153

O2 Sensor Circuit Slow Response (Bank 2 Sensor 1)

P0154

O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 1)

P0157

O2 Sensor Circuit Low Voltage (Bank 2 Sensor 2)

P0158

O2 Sensor Circuit High Voltage (Bank 2 Sensor 2)

P0159

O2 Sensor Circuit Slow Response (Bank 2 Sensor 2)

P0160

O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 2)

P0161

O2 Sensor Heater Circuit (Bank2 Sensor2)

P0171

System Too Lean (Bank 1)

P0172

System Too Rich (Bank 1)

P0174

System Too Lean (Bank 2)

Index













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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0175 P0181

P0182

P0183

P0196

P0197 P0198

P0222

P0223

P0230 P0301 P0302 P0303 P0304 P0305 P0306 P0327

P0328

P0332 P0333

P0335

P0336

Item System Too Rich (Bank 2)

Index

Fuel Temperature Sensor “A” Circuit Fuel Temperature Sensor “A” Circuit Fuel Temperature Sensor “A” Circuit Engine Oil Temperature Sensor Cir- Engine Oil Temperature Sensor Low Engine Oil Temperature Sensor High Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Fuel Pump Primary Circuit

Cylinder 1 Misfire Detected

Cylinder 2 Misfire Detected

Cylinder 3 Misfire Detected

Cylinder 4 Misfire Detected

Cylinder 5 Misfire Detected

Cylinder 6 Misfire Detected

Knock Sensor 1 Circuit Low (Bank 1 Knock Sensor 1 Circuit High (Bank 1 Knock Sensor 2 Circuit Low (Bank 2) Knock Sensor 2 Circuit High (Bank 2) Crankshaft Position Sensor “A” Cir Crankshaft Position Sensor “A” Cir

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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0340

Item Camshaft Position Sensor “A” Circuit (Bank 1 or Single Sensor)

P0345

Camshaft Position Sensor “A” Circuit (Bank 2)

P0365

Camshaft Position Sensor “B” Circuit (Bank 1)

P0390

Camshaft Position Sensor “B” Circuit (Bank 2)

P0400

Exhaust Gas Recirculation Flow

P0420

Catalyst System Efficiency Below Threshold (Bank 1)

P0442

Evaporative Emission Control System Leak Detected (Small Leak)

P0447

Evaporative Emission Control System Vent Control Circuit Open

P0448

Evaporative Emission Control System Vent Control Circuit Shorted

P0451

Evaporative Emission Control System Pressure Sensor

P0452

Evaporative Emission Control System Pressure Sensor Low Input

P0453

Evaporative Emission Control System Pressure Sensor High Input

P0456

Evaporative Emission Control System Leak Detected (Very Small Leak)

P0457

Evaporative Emission Control Sys Evaporative Emission System Purge Evaporative Emission System Purge Fuel Level Sensor “A” Circuit Range/ Fuel Level Sensor “A” Circuit Low

Fuel Level Sensor “A” Circuit High

Fuel Level Sensor Circuit Intermittent

P0458

P0459

P0461

P0462 P0463 P0464

Index









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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P0500

Item Vehicle Speed Sensor “A”

P0506

Idle Air Control System RPM Lower Than Expected

P0507

Idle Air Control System RPM Higher Than Expected

P0512

Starter Request Circuit

P0513

Incorrect Immobilizer Key

P0604

Internal Control Module Random Access Memory (RAM) Error

P0605

Internal Control Module Read Only Memory (ROM) Error

P0607

Throttle Control System Circuit Range/Performance

P0638

Throttle Actuator Control Range/Performance (Bank 1)

P0700

Transmission Control System (MIL Request)

P1152

O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1)

P1153

O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1)

P1154

O2 Sensor Circuit Range/Performance (Low) (Bank 2 Sensor 1)

P1155

O2 Sensor Circuit Range/Performance (High) (Bank 2 Sensor 1)

P1160

Return Spring Failure

P1443

Vent Control Solenoid Valve Function Problem

P1492

EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input)

P1493

EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input)

P1494

EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input)

P1495

EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input)

Index













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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P1496

Item EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input)

P1497

EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input)

P1498

EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input)

P1499

EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input)

P1518

Starter Switch Circuit Low Input

P1560

Back-Up Voltage Circuit Malfunction

P1570

Antenna

P1571

Reference Code Incompatibility

P1572

IMM Circuit Failure (Except Antenna Circuit)

P1574

Key Communication Failure

P1576

EGI Control Module EEPROM

P1577

IMM Control Module EEPROM

P1578

Meter Failure

P1602

Control Module Programming Error

P2088

Intake Camshaft Position Actuator Control Circuit Low (Bank 1)

P2089

Intake Camshaft Position Actuator Control Circuit High (Bank 1)

P2090

Exhaust Camshaft Position Actuator Control Circuit Low (Bank 1)

P2091

Exhaust Camshaft Position Actuator Control Circuit High (Bank 1)

P2092

Intake Camshaft Position Actuator Control Circuit Low (Bank 2)

P2093

Intake Camshaft Position Actuator Control Circuit High (Bank 2)

P2094

Exhaust Camshaft Position Actuator Control Circuit Low (Bank 2)

Index















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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC P2095

Item Exhaust Camshaft Position Actuator Control Circuit High (Bank 2)

P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

P2098

Post Catalyst Fuel Trim System Too Lean (Bank 2)

P2099

Post Catalyst Fuel Trim System Too Rich (Bank 2)

P2101

Throttle Actuator Control Motor Circuit Range/Performance

P2102

Throttle Actuator Control Motor Circuit Low

P2103

Throttle Actuator Control Motor Circuit High

P2109

Throttle/Pedal Position Sensor “A” Minimum Stop Performance

P2122

Throttle/Pedal Position Sensor/ Switch “D” Circuit Low Input

P2123

Throttle/Pedal Position Sensor/ Switch “D” Circuit High Input

P2127

Throttle/Pedal Position Sensor/ Switch “E” Circuit Low Input

P2128

Throttle/Pedal Position Sensor/ Switch “E” Circuit High Input

P2135

Throttle/Pedal Position Sensor/ Switch “A”/“B” Voltage Correlation

P2138

Throttle/Pedal Position Sensor/ Switch “D”/“E” Voltage Correlation

P2227

Atmospheric Pressure Sensor Range/Performance

P2228

Barometric Pressure Circuit Low

P2229

Barometric Pressure Circuit High

U0073

CAN Failure, Bus ‘OFF’ Detection

U0101

CAN (TCU) Data not Loaded

Index













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List of Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) DTC U0122

Item CAN (VDC) Data not Loaded

U0140

CAN (BCU) Data not Loaded

U0402

CAN (TCU) Data Abnormal

U0416

CAN (VDC) Data Abnormal

U0422

CAN (BCU) Data Abnormal

Index



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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

18.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Check the AVCS system operating angle using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the AVCS system operating angle approximately 0°?

Yes Go to step 2.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft)

When the oil flow control solenoid valve duty output exceeds 10%, is the AVCS system operating angle approx. 0°?

Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft)

Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

B: DTC P0014 EXHAUST AVCS SYSTEM 1 (RANGE/PERFORMANCE) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Check the exhaust AVCS system operating angle using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the exhaust AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Yes Go to step 2. Is the exhaust AVCS system operating angle approximately 0°?

When the oil flow control solenoid valve duty output exceeds 10%, is the exhaust AVCS system operating angle approx. 0°?

EN(H6DO)(diag)-92

Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft)

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft) Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

C: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the AVCS system operating angle approx. 0°, and oil flow control solenoid valve duty output approx. 10%?

EN(H6DO)(diag)-93

Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft) • Timing chain (matching of timing mark)

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

D: DTC P0017 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the exhaust AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the exhaust AVCS system operating angle approx. 0°, and oil flow control solenoid valve duty output approx. 10%?

EN(H6DO)(diag)-94

Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft) • Timing chain (matching of timing mark)

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

E: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the AVCS system operating angle approx. 0°, and oil flow control solenoid valve duty output approx. 10%?

EN(H6DO)(diag)-95

Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft) • Timing chain (matching of timing mark)

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

F: DTC P0019 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Measure the exhaust AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the exhaust AVCS system operating angle approx. 0°, and oil flow control solenoid valve duty output approx. 10%?

EN(H6DO)(diag)-96

Yes Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft) • Timing chain (matching of timing mark)

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

G: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Check the AVCS system operating angle using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the AVCS system operating angle approximately 0°?

Yes Go to step 2.

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft)

When the oil flow control solenoid valve duty output exceeds 10%, is the AVCS system operating angle approx. 0°?

Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Intake camshaft (dirt, damage of camshaft)

Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

EN(H6DO)(diag)-97

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

H: DTC P0024 EXHAUST AVCS SYSTEM 2 (RANGE/PERFORMANCE) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK CURRENT DATA. 1) Start the engine and let it idle. 2) Check the exhaust AVCS system operating angle using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK CURRENT DATA. 1) Drive with acceleration and deceleration at 80 km/h (50 MPH) or less. NOTE: Drive to an extent that the duty output of oil flow control solenoid valve increases. 2) Measure the exhaust AVCS system operating angle and oil flow control solenoid valve duty output using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Yes Go to step 2. Is the exhaust AVCS system operating angle approximately 0°?

When the oil flow control solenoid valve duty output exceeds 10%, is the exhaust AVCS system operating angle approx. 0°?

EN(H6DO)(diag)-98

Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft)

No Check the following item and repair or replace if necessary. • Oil pipe (clog) • Oil flow control solenoid valve (clog or dirt of oil routing, setting of spring) • Exhaust camshaft (dirt, damage of camshaft) Perform the following procedures, and clean the oil routing. Replace the engine oil and idle the engine for 5 minutes, and then replace the oil filter and engine oil.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

I:

DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-99

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Start and warm up the engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 4) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 5 — (E47) No. 1: (B136) No. 6 — (E47) No. 1: (B136) No. 19 — (E47) No. 3: (B136) No. 18 — (E47) No. 4: Is the resistance 2 — 3 Ω? Go to step 3. CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 2 — No. 1:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector

Replace the front oxygen (A/F) sensor. CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact of ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor.

EN(H6DO)(diag)-100

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

J: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-101

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY TO FRONT OXY- Is the voltage 10 V or more? GEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between front oxygen (A/F) sensor connector and engine ground. Connector & terminal (E47) No. 2 (+) — Engine ground (–):

Yes Go to step 2.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 5 — (E47) No. 1: (B136) No. 6 — (E47) No. 1:

3

CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground:

Is the resistance less than 5 Ω? Go to step 4.

4

CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 2 — No. 1:

Is the resistance 2 — 3 Ω?

EN(H6DO)(diag)-102

Repair the poor contact of ECM connector.

No Repair the power supply line. NOTE: In this case, repair the following item: • Open circuit in harness between A/F, oxygen sensor relay and front oxygen (A/F) sensor connector • Poor contact of A/F, oxygen sensor relay connector • Poor contact of coupling connector • Fault of A/F, oxygen sensor relay Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector Replace the front oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

K: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-103

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 5 (+) — Chassis ground (–): (B136) No. 6 (+) — Chassis ground (–): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? 1) Disconnect the connector from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground:

EN(H6DO)(diag)-104

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector.

Repair the poor contact of ECM connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

L: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY REAR OXYGEN SENSOR LH

3

4

1

10

9

3

2

4

16

E25

11

1

15

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

13

B220

14

A/F, OXYGEN SENSOR RELAY

E61

12

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-105

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY TO REAR OXYIs the voltage 10 V or more? GEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and engine ground. Connector & terminal (E61) No. 2 (+) — Engine ground (–):

Yes Go to step 2.

2

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between the ECM and oxygen sensor connector. Connector & terminal (B135) No. 6 — (E61) No. 1:

Is the resistance less than 1 Ω? Go to step 3.

3

CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground:

Is the resistance less than 5 Ω? Go to step 4.

4

CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor connector terminals. Terminals No. 2 — No. 1:

Is the resistance 5 — 7 Ω?

EN(H6DO)(diag)-106

Repair the poor contact of ECM connector.

No Repair the power supply line. NOTE: In this case, repair the following item: • Open circuit in harness between A/F, oxygen sensor relay and rear oxygen sensor connector • Poor contact of A/F, oxygen sensor relay connector • Poor contact of coupling connector • Fault of A/F, oxygen sensor relay Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector Replace the rear oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

M: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY REAR OXYGEN SENSOR LH

3

4

1

10

9

3

2

4

16

E25

11

1

15

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

13

B220

14

A/F, OXYGEN SENSOR RELAY

E61

12

E3 B22

B503

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

J/C

C20

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

Step CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 6 (+) — Chassis ground (–):

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

5 6 14 15 16 25 26 27 33 34 35

34 42

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

Check Is the voltage 10 V or more?

EN(H6DO)(diag)-107

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and rear oxygen sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check Yes CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? Repair the poor 1) Disconnect the connector from ECM. contact of ECM 2) Measure the resistance between ECM and connector. chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground:

EN(H6DO)(diag)-108

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

N: DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-109

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Start and warm up the engine. 2) Turn the ignition switch to OFF. 3) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 4) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 1 — (E24) No. 1: (B135) No. 2 — (E24) No. 1: (B135) No. 8 — (E24) No. 3: (B135) No. 20 — (E24) No. 4: Is the resistance 2 — 3 Ω? Go to step 3. CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 2 — No. 1:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector

Replace the front oxygen (A/F) sensor. CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact of ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor.

EN(H6DO)(diag)-110

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

O: DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-111

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY TO FRONT OXY- Is the voltage 10 V or more? GEN (A/F) SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between front oxygen (A/F) sensor connector and engine ground. Connector & terminal (E24) No. 2 (+) — Engine ground (–):

Yes Go to step 2.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 1 — (E24) No. 1: (B135) No. 2 — (E24) No. 1:

3

CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground:

Is the resistance less than 5 Ω? Go to step 4.

4

CHECK FRONT OXYGEN (A/F) SENSOR. Measure the resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 2 — No. 1:

Is the resistance 2 — 3 Ω?

EN(H6DO)(diag)-112

Repair the poor contact of ECM connector.

No Repair the power supply line. NOTE: In this case, repair the following item: • Open circuit in harness between A/F, oxygen sensor relay and front oxygen (A/F) sensor connector • Poor contact of A/F, oxygen sensor relay connector • Poor contact of coupling connector • Fault of A/F, oxygen sensor relay Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector Replace the front oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

P: DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-113

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 1 (+) — Chassis ground (–): (B135) No. 2 (+) — Chassis ground (–): CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? 1) Disconnect the connector from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground:

EN(H6DO)(diag)-114

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector.

Repair the poor contact of ECM connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

Q: DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY REAR OXYGEN SENSOR LH

3

4

1

10

9

3

2

4

16

E25

11

1

15

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

13

B220

14

A/F, OXYGEN SENSOR RELAY

E61

12

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-115

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY TO REAR OXYIs the voltage 10 V or more? GEN SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from rear oxygen sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between rear oxygen sensor connector and engine ground. Connector & terminal (E25) No. 2 (+) — Engine ground (–):

Yes Go to step 2.

2

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between the ECM and oxygen sensor connector. Connector & terminal (B135) No. 5 — (E25) No. 1:

Is the resistance less than 1 Ω? Go to step 3.

3

CHECK GROUND CIRCUIT FOR ECM. Measure the resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground:

Is the resistance less than 5 Ω? Go to step 4.

4

CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor connector terminals. Terminals No. 2 — No. 1:

Is the resistance 5 — 7 Ω?

EN(H6DO)(diag)-116

Repair the poor contact of ECM connector.

No Repair the power supply line. NOTE: In this case, repair the following item: • Open circuit in harness between A/F, oxygen sensor relay and rear oxygen sensor connector • Poor contact of A/F, oxygen sensor relay connector • Poor contact of coupling connector • Fault of A/F, oxygen sensor relay Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector Replace the rear oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

R: DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY REAR OXYGEN SENSOR LH

3

4

1

10

9

3

2

4

16

E25

11

1

15

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

13

B220

14

A/F, OXYGEN SENSOR RELAY

E61

12

E3 B22

B503

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

J/C

C20

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

Step CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 5 (+) — Chassis ground (–):

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

5 6 14 15 16 25 26 27 33 34 35

34 42

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

Check Is the voltage 10 V or more?

EN(H6DO)(diag)-117

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and rear oxygen sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check Yes CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Ω? Repair the poor 1) Disconnect the connector from ECM. contact of ECM 2) Measure the resistance between ECM and connector. chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground:

EN(H6DO)(diag)-118

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

S: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

3

4

Step CHECK AIR INTAKE SYSTEM.

Check Yes Are there holes, loose bolts or Repair the air disconnection of hose on air intake system. intake system? CHECK MANIFOLD ABSOLUTE PRESSURE Is the measured value 73.3 — Go to step 3. SENSOR. 106.6 kPa (550 — 800 mmHg, 1) Start the engine and warm up engine until 21.65 — 31.50 inHg) when the coolant temperature is higher than 75°C ignition is turned ON, and 20.0 (167°F). — 46.7 kPa (150 — 350 mmHg, 2) Place the select lever in “P” range or “N” 5.91 — 13.78 inHg) during range. idling? 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of intake manifold pressure sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the “General Scan Tool Instruction Manual”. CHECK THROTTLE OPENING ANGLE. Is the measured value less than Go to step 4. Read the data of throttle position signal using 5% when throttle is fully Subaru Select Monitor or general scan tool. closed? NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the “General Scan Tool Instruction Manual”. CHECK THROTTLE OPENING ANGLE. Is the measured value 85% or Replace the manimore when throttle is fully fold absolute presopen? sure sensor.

EN(H6DO)(diag)-119

No Go to step 2.

Replace the manifold absolute pressure sensor.

Replace the electronic throttle control.

Replace the electronic throttle control.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

T: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H6DO)(diag)-120

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the mass air flow and intake air temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

U: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2

2

1

4

5

3

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

B3 B83 J/C

B30

C31

C11

C22

C10

* *

B : B135

*

ECM C : B136

E

B220 B3

B83

1 2 3 4 5

1 2 3 4 5 6 7 8

1 3 4 2

5 7 8 6

9 11 12 10

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07771

EN(H6DO)(diag)-121

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the voltage less than 0.2 V? Go to step 2. 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK POWER SUPPLY OF MASS AIR Is the voltage 10 V or more? FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from mass air flow and intake air temperature sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 3 (+) — Engine ground (–):

3

CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and the mass air flow and intake air temperature sensor connector. Connector & terminal (B136) No. 22 — (B3) No. 5: CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 22 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM and mass air flow and intake air temperature sensor connector.

4

5

Go to step 3.

Is the resistance less than 1 Ω? Go to step 4.

Is the resistance 1 MΩ or more?

Is there poor contact of the ECM or the mass air flow and intake air temperature sensor connector?

EN(H6DO)(diag)-122

Go to step 5.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between main relay and mass air flow and intake air temperature sensor connector • Poor contact of main relay connector Repair the open circuit of harness between the ECM and mass air flow and intake air temperature sensor connector.

Repair the ground short circuit of harness between ECM and mass air flow and intake air temperature sensor connector. Repair the poor Replace the mass contact of ECM or air flow and intake mass air flow and air temperature intake air tempera- sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

V: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2

2

1

4

5

3

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

B3 B83 J/C

B30

C31

C11

C22

C10

* *

B : B135

*

ECM C : B136

E

B220 B3

B83

1 2 3 4 5

1 2 3 4 5 6 7 8

1 3 4 2

5 7 8 6

9 11 12 10

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07771

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check CHECK CURRENT DATA. Is the voltage 5 V or more? 1) Start the engine. 2) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Yes Go to step 2.

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from mass air flow and intake air temperature sensor. 3) Start the engine. 4) Read the data of air flow sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 4 — Engine ground:

Repair the short circuit of harness to power supply between ECM and mass air flow and intake air temperature sensor connector.

CHECK FOR POOR CONTACT. Check for poor contact of mass air flow and intake air temperature sensor connector.

Go to step 4.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and mass air flow and intake air temperature sensor connector. • Poor contact of ECM connector Is there poor contact in the Repair any poor Replace the mass mass air flow and intake air contact of the air flow and intake temperature sensor connector? mass air flow and air temperature intake air tempera- sensor.

EN(H6DO)(diag)-124

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

W: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3

MANIFOLD ABSOLUTE PRESSURE SENSOR

E21

5 8 1

E77 E76

6 23 28

E2

A29 D20 A19

B21

A : B134 ECM D : B137

B21 E21

1 2 3

E77

1 2 3 4 5 6 7 8 9 10

A : B134 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D : B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07574

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the measured value less than Go to step 2. 1) Start the engine. 13.3 kPa (100 mmHg, 3.94 2) Read the data of intake manifold absolute inHg)? pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK POWER SUPPLY OF MANIFOLD ABSOLUTE PRESSURE SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 3 (+) — Engine ground (–):

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and manifold absolute pressure sensor connector. Connector & terminal (B137) No. 20 — (E21) No. 2:

4

CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 20 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM and manifold absolute pressure sensor connector.

5

Is the voltage 4.5 V or more?

Is the resistance 1 MΩ or more?

Go to step 3.

Go to step 5.

Is there poor contact of ECM or Repair the poor manifold absolute pressure contact of ECM or sensor connector? manifold absolute pressure sensor connector.

EN(H6DO)(diag)-126

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and manifold absolute pressure sensor connector. • Poor contact of ECM connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and manifold absolute pressure sensor connector. • Poor contact of coupling connector Repair ground short circuit of harness between ECM and manifold absolute pressure sensor connector. Replace the manifold absolute pressure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

X: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3

MANIFOLD ABSOLUTE PRESSURE SENSOR

E21

5 8 1

E77 E76

6 23 28

E2

A29 D20 A19

B21

A : B134 ECM D : B137

B21 E21

1 2 3

E77

1 2 3 4 5 6 7 8 9 10

A : B134 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

D : B137 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07574

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Go to step 2. Is the measured value 119.5 1) Start the engine. kPa (896.5 mmHg, 35.29 inHg) 2) Read the data of intake manifold absolute or more? pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manifold absolute pressure sensor. 3) Start the engine. 4) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between manifold absolute pressure sensor connector and engine ground. Connector & terminal (E21) No. 1 — Engine ground:

Is the measured value 119.5 Repair the short kPa (896.5 mmHg, 35.29 inHg) circuit of harness or more? to power supply between ECM and manifold absolute pressure sensor connector.

CHECK FOR POOR CONTACT. Check for poor contact of manifold absolute pressure sensor connector.

Is there poor contact of manifold absolute pressure sensor connector?

Is the resistance less than 5 Ω? Go to step 4.

EN(H6DO)(diag)-128

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and manifold absolute pressure sensor connector. • Poor contact of ECM connector • Poor contact of coupling connector Repair the poor Replace the manicontact of manifold absolute presfold absolute pres- sure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

Y: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK ENGINE COOLANT TEMPERAIs the temperature 75°C TURE. (167°F) or more? 1) Start the engine and warm up completely. 2) Measure the engine coolant temperature using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H6DO)(diag)-129

Yes Replace the mass air flow and intake air temperature sensor.

No Check for DTC P0125.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

Z: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2

2

1

4

5

3

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

B3 B83 J/C

B30

C31

C11

C22

C10

* *

B : B135

*

ECM C : B136

E

B220 B3

B83

1 2 3 4 5

1 2 3 4 5 6 7 8

1 3 4 2

5 7 8 6

9 11 12 10

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the intake air temperature 1) Start the engine. 120°C (248°F) or more? 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Yes Go to step 2.

CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or MASS AIR FLOW AND INTAKE AIR TEMmore? PERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and mass air flow and intake air temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 31 — Chassis ground:

Replace the mass air flow and intake air temperature sensor.

EN(H6DO)(diag)-131

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the ground short circuit of harness between ECM and mass air flow and intake air temperature sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AA:DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2

2

1

4

5

3

MASS AIR FLOW & INTAKE AIR TEMPERATURE SENSOR

B3 B83 J/C

B30

C31

C11

C22

C10

* *

B : B135

*

ECM C : B136

E

B220 B3

B83

1 2 3 4 5

1 2 3 4 5 6 7 8

1 3 4 2

5 7 8 6

9 11 12 10

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check CHECK CURRENT DATA. Is the intake air temperature 1) Start the engine. less than –40°C (–40°F)? 2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK FOR POOR CONTACT. Check for poor contact of ECM and mass air flow and intake air temperature sensor connector.

Is there poor contact of the ECM or the mass air flow and intake air temperature sensor connector?

Yes Go to step 2.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the poor contact of ECM or mass air flow and intake air temperature sensor connector. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. Repair the harness MASS AIR FLOW AND INTAKE AIR TEMand connector. PERATURE SENSOR CONNECTOR. NOTE: 1) Turn the ignition switch to OFF. In this case, repair 2) Disconnect the connector from ECM and the following item: mass air flow and intake air temperature sensor. • Open circuit in 3) Measure the resistance of harness between harness between ECM and the mass air flow and intake air temECM and mass air perature sensor connector. flow and intake air Connector & terminal temperature sen(B136) No. 31 — (B3) No. 1: sor connector. (B135) No. 30 — (B3) No. 2: • Poor contact of joint connector CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? Repair the short Replace the mass MASS AIR FLOW AND INTAKE AIR TEMcircuit of harness air flow and intake PERATURE SENSOR CONNECTOR. to power supply air temperature 1) Connect all connectors. between ECM and sensor. chassis ground. Connector & terminal (B136) No. 31 (+) — Chassis ground (–):

EN(H6DO)(diag)-133

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AB:DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2

ENGINE COOLANT TEMPERATURE SENSOR

E8

6 12

E2

A29 D22

B21

A : B134 ECM D : B137

B21 A : B134

E8

1 2

1 2 8 9 10 18 19 20 28 29 30

D : B137

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07575

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the temperature 150°C 1) Start the engine. (302°F) or more? 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND EN- Is the resistance 1 MΩ or GINE COOLANT TEMPERATURE SENSOR more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and engine coolant temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 22 — Chassis ground:

EN(H6DO)(diag)-135

Yes Go to step 2.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Replace the Repair short cirengine coolant cuit in harness to temperature sen- ground between sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AC:DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2

ENGINE COOLANT TEMPERATURE SENSOR

E8

6 12

E2

A29 D22

B21

A : B134 ECM D : B137

B21 A : B134

E8

1 2

1 2 8 9 10 18 19 20 28 29 30

D : B137

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07575

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Is the engine coolant tempera- Go to step 2. 1) Start the engine. ture less than –40°C (–40°F)? 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Check for poor contact of ECM and engine cool- engine coolant temperature contact of ECM or ant temperature sensor connector. sensor connector? engine coolant temperature sensor connector. CHECK HARNESS BETWEEN ECM AND EN- Is the resistance less than 1 Ω? Go to step 4. GINE COOLANT TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and engine coolant temperature sensor. 3) Measure the resistance of harness between ECM and engine coolant temperature sensor connector. Connector & terminal (B134) No. 29 — (E8) No. 1: (B137) No. 22 — (E8) No. 2: CHECK HARNESS BETWEEN ECM AND EN- Is the voltage 5 V or more? GINE COOLANT TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 22 (+) — Chassis ground (–):

EN(H6DO)(diag)-137

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and engine coolant temperature sensor connector • Poor contact of coupling connector Repair the short Replace the circuit of harness engine coolant to power supply temperature senbetween ECM and sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AD:DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: ELECTRONIC THROTTLE CONTROL RELAY BATTERY

B220 M/B No. 13 16 15 M/B No. 16 13 14

B7

B17

MAIN RELAY

ECM

C4

D : B137 A28 A18

C : B136 A19 A1 A2 A29

B : B135

A3 D5 D3 D1 A4 A6

A : B134

B138

* *

24 25

28 39 38 6

35 37 34 40 36

B21

E

J/C

ELECTRONIC THROTTLE CONTROL

E

1 2 3 4 5 6 7 8

1 2 3 4 5 6

B220

1 3 4 2

5 7 8 6

A : B134

B138

E57

9 11 12 10

4 6

5 1 2 3

E2

1 2 8 9 10 18 19 20 28 29 30

17 18 20 21 19

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

*

E

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

C : B136

13 15 16 14

E57

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07772

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Replace the electronic throttle control.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective.

EN(H6DO)(diag)-139

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AE:DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: ELECTRONIC THROTTLE CONTROL RELAY BATTERY

B220 M/B No. 13 16 15 M/B No. 16 13 14

B7

B17

MAIN RELAY

ECM

C4

D : B137 A28 A18

C : B136 A19 A1 A2 A29

B : B135

A3 D5 D3 D1 A4 A6

A : B134

B138

* *

24 25

28 39 38 6

35 37 34 40 36

B21

E

J/C

ELECTRONIC THROTTLE CONTROL

E

1 2 3 4 5 6 7 8

1 2 3 4 5 6

B220

1 3 4 2

5 7 8 6

A : B134

B138

E57

9 11 12 10

4 6

5 1 2 3

E2

1 2 8 9 10 18 19 20 28 29 30

17 18 20 21 19

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

*

E

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

C : B136

13 15 16 14

E57

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07772

EN(H6DO)(diag)-140

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 29 — (E57) No. 3:

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 3. ELECTRONIC THROTTLE CONTROL. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

3

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18:

4

EN(H6DO)(diag)-141

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector. Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AF:DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Engine does not return to idle. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

3

Step CHECK TIRE SIZE.

CHECK ENGINE COOLANT. Check the following items: • Amount of engine coolant • Engine coolant freeze • Contamination of engine coolant CHECK THERMOSTAT.

Check Yes Is the tire size as specified and Go to step 2. the same size as three other wheels? Is the engine coolant normal? Go to step 3.

Does the thermostat remain opened?

EN(H6DO)(diag)-142

Replace the thermostat.

No Replace the tire.

Fill or replace the engine coolant.

Replace the engine coolant temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AG:DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2

ENGINE COOLANT TEMPERATURE SENSOR

E8

6 12

E2

A29 D22

B21

A : B134 ECM D : B137

B21 A : B134

E8

1 2

1 2 8 9 10 18 19 20 28 29 30

D : B137

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07575

EN(H6DO)(diag)-143

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. Measure the resistance between engine coolant temperature sensor terminals when the engine coolant is cold and after warmed up. Terminals No. 1 — No. 2:

Check Yes Is the resistance of engine cool- Repair the poor ant temperature sensor differ- contact of ECM ent between when engine connector. coolant is cold and after warmed up?

EN(H6DO)(diag)-144

No Replace the engine coolant temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AH:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Thermostat remains open. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK ENGINE COOLANT.

Check Is the engine coolant amount normal?

CHECK RADIATOR FAN. 1) Start the engine. 2) Check the radiator fan operation.

Does the radiator fan continuously rotate for 3 minutes or more during idling?

EN(H6DO)(diag)-145

Yes Go to step 2.

No Refill the engine coolant. Repair radiator fan Replace the thercircuit. and

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AI: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

B22

B503 1 2 3 4 5 6 7 8

1 2 3 4

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H6DO)(diag)-146

38 45 51

39 52

40 46 53

41 47 54

EN-07769

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 18 — Chassis ground: (B136) No. 19 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of the front oxygen (A/F) sensor connector.

Check Is the resistance 1 MΩ or more?

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

Is there poor contact of front oxygen (A/F) sensor connector?

Repair the poor contact of front oxygen (A/F) sensor connector.

Replace the front oxygen (A/F) sensor.

EN(H6DO)(diag)-147

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AJ:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

B22

B503 1 2 3 4 5 6 7 8

1 2 3 4

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H6DO)(diag)-148

38 45 51

39 52

40 46 53

41 47 54

EN-07769

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 8 V or more? FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 18 (+) — Chassis ground (–): (B136) No. 19 (+) — Chassis ground (–):

EN(H6DO)(diag)-149

Yes Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector.

No Replace the front oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AK:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust system? NOTE: Check the following items. • Loose installation of front portion of exhaust pipe onto cylinder heads • Loose connection between front exhaust pipe and front catalytic converter • Damage of exhaust pipe resulting in a hole

EN(H6DO)(diag)-150

Yes No Repair the exhaust Replace the front system. oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AL:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-151

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 19 — (E47) No. 3: (B136) No. 18 — (E47) No. 4:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact of ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor.

EN(H6DO)(diag)-152

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AM:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY REAR OXYGEN SENSOR LH

3

4

1

10

9

3

2

4

16

E25

11

1

15

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

13

B220

14

A/F, OXYGEN SENSOR RELAY

E61

12

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-153

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 490 mV or more? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E61) No. 3: (B135) No. 30 — (E61) No. 4:

4

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E61) No. 3 (+) — Chassis ground (–):

5

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Loose part and improper installation between front oxygen (A/F) sensor and rear oxygen sensor

Is the voltage 0.2 — 0.5 V?

EN(H6DO)(diag)-154

No Go to step 2.

Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair or replace Replace the rear faulty parts. oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AN:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY REAR OXYGEN SENSOR LH

3

4

1

10

9

3

2

4

16

E25

11

1

15

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

13

B220

14

A/F, OXYGEN SENSOR RELAY

E61

12

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-155

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 250 mV or less? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E61) No. 3: (B135) No. 30 — (E61) No. 4:

4

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E61) No. 3 (+) — Chassis ground (–):

5

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Loose part and improper installation between front oxygen (A/F) sensor and rear oxygen sensor

Is the voltage 0.2 — 0.5 V?

EN(H6DO)(diag)-156

No Go to step 2.

Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair or replace Replace the rear faulty parts. oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AO:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY REAR OXYGEN SENSOR LH

3

4

1

10

9

3

2

4

16

E25

11

1

15

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

13

B220

14

A/F, OXYGEN SENSOR RELAY

E61

12

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-157

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E61) No. 3:

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. Measure the resistance between rear oxygen sensor connector and chassis ground. Connector & terminal (E61) No. 3 — Chassis ground: CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor terminals. Terminals No. 3 — No. 4

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Is the resistance 1 MΩ or Go to step 3. Repair the ground more? short circuit of harness between ECM and rear oxygen sensor connector. Is the resistance less than 1 Ω? Replace the rear Even if DTC is oxygen sensor. detected, the cir duce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

EN(H6DO)(diag)-158

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AP:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

3

E25

2

2

9 10

REAR OXYGEN SENSOR RH

3

M/B No. 15 12 11

4

REAR OXYGEN SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E61

9

10

11

12

16

15

13

14

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-159

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E61) No. 3: (B135) No. 30 — (E61) No. 4:

Check Yes Is the voltage 490 mV or more? Go to step 6.

No Go to step 2.

Is the voltage 250 mV or less? Go to step 6.

Go to step 3.

Has water entered the connec- Completely tor? remove any water inside. Is the resistance less than 1 Ω? Go to step 5.

Go to step 4.

EN(H6DO)(diag)-160

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

5

6

Step CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E61) No. 3 (+) — Chassis ground (–):

Check Is the voltage 0.2 — 0.5 V?

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Loose part and improper installation between front oxygen (A/F) sensor and rear oxygen sensor

Yes Replace the rear oxygen sensor.

Repair or replace faulty parts.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Replace the rear oxygen sensor.

AQ:DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2) NOTE: Refer to DTC P0037 for diagnostic procedure.

EN(H6DO)(diag)-161

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AR:DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

B22

B503 1 2 3 4 5 6 7 8

1 2 3 4

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H6DO)(diag)-162

38 45 51

39 52

40 46 53

41 47 54

EN-07769

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 8 — Chassis ground: (B135) No. 20 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of the front oxygen (A/F) sensor connector.

Check Is the resistance 1 MΩ or more?

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

Is there poor contact of front oxygen (A/F) sensor connector?

Repair the poor contact of front oxygen (A/F) sensor connector.

Replace the front oxygen (A/F) sensor.

EN(H6DO)(diag)-163

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AS:DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

B22

B503 1 2 3 4 5 6 7 8

1 2 3 4

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H6DO)(diag)-164

38 45 51

39 52

40 46 53

41 47 54

EN-07769

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 8 V or more? FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from front oxygen (A/F) sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 8 (+) — Chassis ground (–): (B135) No. 20 (+) — Chassis ground (–):

EN(H6DO)(diag)-165

Yes Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector.

No Replace the front oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AT:DTC P0153 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK EXHAUST SYSTEM. Is there any fault in exhaust system? NOTE: Check the following items. • Loose installation of front portion of exhaust pipe onto cylinder heads • Loose connection between front exhaust pipe and front catalytic converter • Damage of exhaust pipe resulting in a hole

EN(H6DO)(diag)-166

Yes No Repair the exhaust Replace the front system. oxygen (A/F) sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AU:DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-167

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and front oxygen (A/F) sensor connector. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 8 — (E24) No. 3: (B135) No. 20 — (E24) No. 4:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Replace the front Check for poor contact of ECM and front oxygen front oxygen (A/F) sensor con- contact of ECM or oxygen (A/F) sen(A/F) sensor connector. nector? front oxygen (A/F) sor.

EN(H6DO)(diag)-168

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AV:DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY REAR OXYGEN SENSOR LH

3

4

1

10

9

3

2

4

16

E25

11

1

15

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

13

B220

14

A/F, OXYGEN SENSOR RELAY

E61

12

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-169

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 490 mV or more? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 28 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

4

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

5

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Loose part and improper installation between front oxygen (A/F) sensor and rear oxygen sensor

Is the voltage 0.2 — 0.5 V?

EN(H6DO)(diag)-170

No Go to step 2.

Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair or replace Replace the rear faulty parts. oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AW:DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY REAR OXYGEN SENSOR LH

3

4

1

10

9

3

2

4

16

E25

11

1

15

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

13

B220

14

A/F, OXYGEN SENSOR RELAY

E61

12

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-171

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK REAR OXYGEN SENSOR DATA. Is the voltage 250 mV or less? Go to step 5. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside. CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 28 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

4

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

5

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Loose part and improper installation between front oxygen (A/F) sensor and rear oxygen sensor

Is the voltage 0.2 — 0.5 V?

EN(H6DO)(diag)-172

No Go to step 2.

Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair or replace Replace the rear faulty parts. oxygen sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AX:DTC P0159 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY REAR OXYGEN SENSOR LH

3

4

1

10

9

3

2

4

16

E25

11

1

15

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

13

B220

14

A/F, OXYGEN SENSOR RELAY

E61

12

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-173

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 28 — (E25) No. 3:

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. Measure the resistance between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 — Chassis ground: CHECK REAR OXYGEN SENSOR. Measure the resistance between rear oxygen sensor terminals. Terminals No. 3 — No. 4

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Is the resistance 1 MΩ or Go to step 3. Repair the ground more? short circuit of harness between ECM and rear oxygen sensor connector. Is the resistance less than 1 Ω? Replace the rear Even if DTC is oxygen sensor. detected, the cir duce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

EN(H6DO)(diag)-174

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

AY:DTC P0160 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK2 SENSOR2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

3

E25

2

2

9 10

REAR OXYGEN SENSOR RH

3

M/B No. 15 12 11

4

REAR OXYGEN SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E61

9

10

11

12

16

15

13

14

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-175

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 28 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

Check Yes Is the voltage 490 mV or more? Go to step 6.

No Go to step 2.

Is the voltage 250 mV or less? Go to step 6.

Go to step 3.

Has water entered the connec- Completely tor? remove any water inside. Is the resistance less than 1 Ω? Go to step 5.

Go to step 4.

EN(H6DO)(diag)-176

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

5

6

Step CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Check Is the voltage 0.2 — 0.5 V?

CHECK EXHAUST SYSTEM. Is there any fault in exhaust Check exhaust system parts. system? NOTE: Check the following items. • Looseness and improper fitting of exhaust system parts • Damage (crack, hole etc.) of parts • Loose part and improper installation between front oxygen (A/F) sensor and rear oxygen sensor

Yes Replace the rear oxygen sensor.

Repair or replace faulty parts.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Replace the rear oxygen sensor.

AZ:DTC P0161 O2 SENSOR HEATER CIRCUIT (BANK2 SENSOR2) NOTE: Refer to DTC P0057 for diagnostic procedure.

BA:DTC P0171 SYSTEM TOO LEAN (BANK 1) NOTE: Refer to DTC P0175 for diagnostic procedure.

BB:DTC P0172 SYSTEM TOO RICH (BANK 1) NOTE: Refer to DTC P0175 for diagnostic procedure.

BC:DTC P0174 SYSTEM TOO LEAN (BANK 2) NOTE: Refer to DTC P0175 for diagnostic procedure.

EN(H6DO)(diag)-177

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BD:DTC P0175 SYSTEM TOO RICH (BANK 2) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Engine stalls. • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1 2

3

4

Step CHECK EXHAUST SYSTEM.

Check Are there holes or loose bolts on exhaust system? CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or disconnection of hose on air intake system? CHECK FUEL PRESSURE. Is the measured value 333 — 343 kPa (3.4 — 3.5 kgf/cm2, WARNING: 48.4 — 49.8 psi)? Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the temperature 75°C SENSOR. (167°F) or more? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H6DO)(diag)-178

Yes No Repair the exhaust Go to step 2. system. Repair the air Go to step 3. intake system. Go to step 4.

Repair the following item. Fuel pressure is too high: • Clogged fuel line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel line

Go to step 5.

Replace the engine coolant temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

5

6

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR SIGNAL. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)?

Yes Go to step 6.

Subtract ambient temperature Repair the poor from intake air temperature. Is contact of ECM the obtained value –10 — 50°C connector. (–18 — 90°F)?

EN(H6DO)(diag)-179

No Replace the mass air flow and intake air temperature sensor.

Check the mass air flow and intake air temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BE:DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H6DO)(diag)-180

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the fuel temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BF:DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

2 3

FUEL TEMPERATURE SENSOR

R58

FUEL PUMP ASSY

7 11

R57 R15

3 8

R333 i155

11 5

i3 B38

B83 J/C

C23 B30

* *

B : B135

*

ECM C : B136

R58 1 2 3 4 5 6

B83 1 2 3 4 5 6 7 8

i155 1 3

R57

2 4 5 6 7 8 9 10 11

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B : B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

: TERMINAL No. OPTIONAL ARRANGEMENT

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07779

EN(H6DO)(diag)-181

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the temperature 120°C 1) Start the engine. (248°F) or higher? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

Yes Go to step 2.

CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or FUEL TEMPERATURE SENSOR CONNEC- more? TOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and fuel temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 23 — Chassis ground:

Replace the fuel temperature sensor.

EN(H6DO)(diag)-182

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the ground short circuit of harness between ECM and fuel pump.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BG:DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

2 3

FUEL TEMPERATURE SENSOR

R58

FUEL PUMP ASSY

7 11

R57 R15

3 8

R333 i155

11 5

i3 B38

B83 J/C

C23 B30

* *

B : B135

*

ECM C : B136

R58 1 2 3 4 5 6

B83 1 2 3 4 5 6 7 8

i155 1 3

R57

2 4 5 6 7 8 9 10 11

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B : B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

: TERMINAL No. OPTIONAL ARRANGEMENT

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07779

EN(H6DO)(diag)-183

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK CURRENT DATA. Is the temperature less than – 1) Start the engine. 40°C (–40°F)? 2) Read the data of fuel temperature sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

2

CHECK FOR POOR CONTACT. Is there poor contact of the Repair any poor contact between the ECM and ECM or fuel temperature senfuel temperature sensor connectors. sor connectors?

3

CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and fuel temperature sensor. 3) Measure the resistance of the harness between the ECM and fuel temperature sensor connector. Connector & terminal (B136) No. 23 — (R58) No. 2: (B135) No. 30 — (R58) No. 3:

4

CHECK HARNESS BETWEEN ECM AND FUEL TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 23 (+) — Chassis ground (–):

Yes Go to step 2.

Repair any poor contact between the ECM and fuel temperature sensor connectors. Is the resistance less than 1 Ω? Go to step 4.

Is the voltage 5 V or more?

EN(H6DO)(diag)-184

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel temperature sensor connector • Poor contact of coupling connector Repair the short Replace the fuel circuit to power in temperature senthe harness sor. nector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BH:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H6DO)(diag)-185

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the oil temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BI: DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2

OIL TEMPERATURE SENSOR

E75

6 27

E2

A29 D21

B21

A : B134 ECM D : B137

B21 A : B134

E75

1 2

1 2 8 9 10 18 19 20 28 29 30

D : B137

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07577

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK CURRENT DATA. Is the oil temperature 215°C 1) Start the engine. (419°F) or more? 2) Read the data of oil temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or TEMPERATURE SENSOR CONNECTOR. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and oil temperature sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B137) No. 21 — Chassis ground:

EN(H6DO)(diag)-187

Yes Go to step 2.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Replace the oil Repair the short temperature sen- circuit to ground in sor. connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BJ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2

OIL TEMPERATURE SENSOR

E75

6 27

E2

A29 D21

B21

A : B134 ECM D : B137

B21 A : B134

E75

1 2

1 2 8 9 10 18 19 20 28 29 30

D : B137

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07577

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Is the oil temperature less than Go to step 2. 1) Start the engine. –40°C (–40°F)? 2) Read the data of oil temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK FOR POOR CONTACT. Is there poor contact of ECM or Repair the poor Check for poor contact of ECM and oil tempera- oil temperature sensor connec- contact of ECM or ture sensor connector. tor? oil temperature sensor connector. CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 4. TEMPERATURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and oil temperature sensor. 3) Measure the resistance of harness between ECM and oil temperature sensor connector. Connector & terminal (B134) No. 29 — (E75) No. 1: (B137) No. 21 — (E75) No. 2:

CHECK HARNESS BETWEEN ECM AND OIL Is the voltage 5 V or more? TEMPERATURE SENSOR CONNECTOR. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 21 (+) — Chassis ground (–):

EN(H6DO)(diag)-189

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil temperature sensor connector • Poor contact of coupling connector Repair the short Replace the oil circuit to power temperature sensupply in harness sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BK:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: ELECTRONIC THROTTLE CONTROL RELAY BATTERY

B220 M/B No. 13 16 15 M/B No. 16 13 14

B7

B17

MAIN RELAY

ECM

C4

D : B137 A28 A18

C : B136 A19 A1 A2 A29

B : B135

A3 D5 D3 D1 A4 A6

A : B134

B138

* *

24 25

28 39 38 6

35 37 34 40 36

B21

E

J/C

ELECTRONIC THROTTLE CONTROL

E

1 2 3 4 5 6 7 8

1 2 3 4 5 6

B220

1 3 4 2

5 7 8 6

A : B134

B138

E57

9 11 12 10

4 6

5 1 2 3

E2

1 2 8 9 10 18 19 20 28 29 30

17 18 20 21 19

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

*

E

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

C : B136

13 15 16 14

E57

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 28 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 4 — Engine ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Replace the electronic throttle control.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BL:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: ELECTRONIC THROTTLE CONTROL RELAY BATTERY

B220 M/B No. 13 16 15 M/B No. 16 13 14

B7

B17

MAIN RELAY

ECM

C4

D : B137 A28 A18

C : B136 A19 A1 A2 A29

B : B135

A3 D5 D3 D1 A4 A6

A : B134

B138

* *

24 25

28 39 38 6

35 37 34 40 36

B21

E

J/C

ELECTRONIC THROTTLE CONTROL

E

1 2 3 4 5 6 7 8

1 2 3 4 5 6

B220

1 3 4 2

5 7 8 6

A : B134

B138

E57

9 11 12 10

4 6

5 1 2 3

E2

1 2 8 9 10 18 19 20 28 29 30

17 18 20 21 19

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

*

E

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

C : B136

13 15 16 14

E57

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 2. ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 3. ELECTRONIC THROTTLE CONTROL. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

3

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 4 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 28:

4

EN(H6DO)(diag)-193

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector. Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BM:DTC P0230 FUEL PUMP PRIMARY CIRCUIT DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

B220 FUEL PUMP RELAY R333

R122

FUEL PUMP CU

i155

i3

2 4 1

8 6 7 9 10 5

B38

BATTERY M/B No. 20

20

14 10 4

21

ECM C33 B10

B : B135 C : B136

FUEL PUMP R15

R58

R57 1

5

2

6

M

E

E

i155

R58 R122 1 2

3 4 1 2 5 6 7 8 9 10

3 4

1 3

R57

2 4 5 6 7 8 9 10 11

5 6 B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135 13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step Check CHECK POWER SUPPLY CIRCUIT TO FUEL Is the voltage 10 V or more? PUMP CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel pump control unit. 3) Turn the ignition switch to ON. 4) Measure the voltage between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 8 (+) — Chassis ground (–):

Yes Go to step 2.

CHECK GROUND CIRCUIT OF FUEL PUMP Is the resistance less than 5 Ω? Go to step 3. CONTROL UNIT. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 5 — Chassis ground: CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 Ω? Go to step 4. CONTROL UNIT AND FUEL PUMP CONNECTOR. 1) Disconnect the connector from fuel pump. 2) Measure the resistance of harness between fuel pump control unit and fuel pump connector. Connector & terminal (R122) No. 9 — (R58) No. 5: (R122) No. 10 — (R58) No. 6:

CHECK HARNESS BETWEEN FUEL PUMP Is the resistance 1 MΩ or Go to step 5. CONTROL UNIT AND FUEL PUMP CONNEC- more? TOR. Measure the resistance between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 9 — Chassis ground: (R122) No. 10 — Chassis ground: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 6. FUEL PUMP CONTROL UNIT. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and fuel pump control unit. Connector & terminal (B136) No. 33 — (R122) No. 6: (B135) No. 10 — (R122) No. 7:

EN(H6DO)(diag)-195

No Repair the power supply circuit. NOTE: In this case, repair the following item: • Open or ground short circuit of harness between fuel pump relay connector and fuel pump control unit connector • Poor contact of fuel pump relay connector • Poor contact of coupling connector Repair the open circuit in harness between fuel pump control unit connector and chassis ground. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between fuel pump control unit connector and fuel pump connector • Poor contact of coupling connector Repair the short circuit to ground in harness between fuel pump control unit connector and fuel pump connector. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel pump control unit connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

7

8

Step CHECK HARNESS BETWEEN ECM AND FUEL PUMP CONTROL UNIT. Measure the resistance between fuel pump control unit and chassis ground. Connector & terminal (R122) No. 6 — Chassis ground: (R122) No. 7 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact of ECM and fuel pump control unit connector.

Check Is the resistance 1 MΩ or more?

Yes Go to step 7.

Is there poor contact of ECM or Repair the poor fuel pump control unit connec- contact of ECM or tor? fuel pump control unit connector. CHECK EXPERIENCE OF RUNNING OUT OF Has the vehicle experienced Finish the diagnoFUEL. running out of fuel? sis. NOTE: DTC may be recorded as a result of fuel pump idling while running out of fuel.

No Repair the short circuit to ground in harness between ECM and fuel pump control unit connector. Go to step 8.

Replace the fuel pump control unit.

BN:DTC P0301 CYLINDER 1 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0306.

BO:DTC P0302 CYLINDER 2 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0306.

BP:DTC P0303 CYLINDER 3 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0306.

BQ:DTC P0304 CYLINDER 4 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0306.

BR:DTC P0305 CYLINDER 5 MISFIRE DETECTED NOTE: For the diagnostic procedure, refer to DTC P0306.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BS:DTC P0306 CYLINDER 6 MISFIRE DETECTED DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • Immediately at fault recognition (A misfire which could damage catalyst occurs.) • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Improper idling • Rough driving CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2

24

23

13

12

11

10

ECM

B134

46

47

51

52

53

54

48

B21

FUEL INJECTOR No. 4

FUEL INJECTOR No. 6

FUEL INJECTOR No. 5

B220

E17

E43

E44

1 2

E

B21

E16

E6

E44

1

E43

2

1

E17

2

1

E6

2

1

2

FUEL INJECTOR No. 3

FUEL INJECTOR No. 2

FUEL INJECTOR No. 1

E5

E16

1

E5

2

1

2

E2

1 3 4 2

5 7 8 6

9 11 12 10

B134

13 15 16 14

17 18 20 21 19

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07768

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–): #5 (B134) No. 23 (+) — Chassis ground (–): #6 (B134) No. 24 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Measure the resistance between fuel injector connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 — Engine ground: #2 (E16) No. 1 — Engine ground: #3 (E6) No. 1 — Engine ground: #4 (E17) No. 1 — Engine ground: #5 (E43) No. 1 — Engine ground: #6 (E44) No. 1 — Engine ground: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. Measure the resistance of harness between ECM and fuel injector connector on faulty cylinders. Connector & terminal #1 (B134) No. 10 — (E5) No. 1: #2 (B134) No. 11 — (E16) No. 1: #3 (B134) No. 12 — (E6) No. 1: #4 (B134) No. 13 — (E17) No. 1: #5 (B134) No. 23 — (E43) No. 1: #6 (B134) No. 24 — (E44) No. 1: CHECK FUEL INJECTOR. Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK POWER SUPPLY LINE. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel injector connector of faulty cylinders and engine ground. Connector & terminal #1 (E5) No. 2 (+) — Engine ground (–): #2 (E16) No. 2 (+) — Engine ground (–): #3 (E6) No. 2 (+) — Engine ground (–): #4 (E17) No. 2 (+) — Engine ground (–): #5 (E43) No. 2 (+) — Engine ground (–): #6 (E44) No. 2 (+) — Engine ground (–):

Check Is the voltage 10 V or more?

Yes Go to step 6.

No Go to step 2.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the ground short circuit of harness between ECM and fuel injector connector.

Is the resistance less than 1 Ω? Go to step 4.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel injector connector • Poor contact of coupling connector

Is the resistance 5 — 20 Ω?

Go to step 5.

Replace the faulty fuel injector.

Is the voltage 10 V or more?

Repair the poor contact of all connectors in fuel injector circuit.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between the main relay and fuel injector connector on faulty cylinders • Poor contact of coupling connector • Poor contact of main relay connector

EN(H6DO)(diag)-198

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

7

8

Step CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–): #5 (B134) No. 23 (+) — Chassis ground (–): #6 (B134) No. 24 (+) — Chassis ground (–): CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK INSTALLATION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR.

9

CHECK CRANK PLATE.

10

CHECK INSTALLATION CONDITION OF TIMING CHAIN. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 18252AA000 CRANKSHAFT SOCKET CHECK FUEL LEVEL.

11

12

CHECK STATUS OF MALFUNCTION INDICATOR LIGHT. 1) Clear the memory using the Subaru Select Monitor or general scan tool. 2) Start the engine, and drive the vehicle 10 minutes or more.

Check Is the voltage 10 V or more?

Yes No Repair the short Go to step 7. circuit to power in harness between ECM and fuel injector connector.

Is the resistance 5 — 20 Ω?

Replace the faulty Go to step 8. fuel injector.

Is the camshaft position sensor Tighten the cam- Go to step 9. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. Is the crank sprocket rusted or Replace the crank Go to step 10. the teeth of crank plate broken? plate. Is the timing chain dislocated Correct the instal- Go to step 11. from its proper position? lation condition of timing chain. Refill the fuel so Go to step 12. that fuel meter indication is higher than the “Lower” level. After replenishing fuel, Go to step 13. Does the malfunction indicator Go to step 14. Go to step 13. light illuminate or blink?

Is the fuel meter indication lower than the “Lower” level?

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

13

Step CHECK CAUSE OF MISFIRE.

Check Yes Was the cause of misfire identi- Finish diagnostics fied when the engine is runoperation, if the ning? engine has no abnormality.

14

CHECK AIR INTAKE SYSTEM.

Is there any fault in air intake system?

15

CHECK MISFIRE SYMPTOM. 1) Turn the ignition switch to ON. 2) Read the DTC. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK FOR ANY OTHER DTC ON DISPLAY. Are DTCs P0301 and P0302 displayed? CHECK DTC ON DISPLAY. Are DTCs P0303 and P0304 displayed? CHECK DTC ON DISPLAY. Is DTC P0305 and P0306 displayed? CHECK DTC ON DISPLAY. Is DTC P0301, P0303 and P0305 displayed? CHECK DTC ON DISPLAY. Is DTC P0302, P0304 and P0306 displayed?

16 17 18 19 20

No Repair the poor contact of connector. NOTE: In this case, repair the following item: • Poor contact of ignition coil connector • Poor contact of fuel injector connector on faulty cylinders • Poor contact of ECM connector • Poor contact of coupling connector Go to step 15.

Repair the air intake system. NOTE: Check the following items. • Are there air leaks or air suction caused by loose or dislocated nuts and bolts? • Are there cracks or any disconnection of hoses? Does the Subaru Select Moni- Go to step 21. Go to step 16. tor or general scan tool indicate only one DTC?

EN(H6DO)(diag)-200

Go to step 22.

Go to step 17.

Go to step 23.

Go to step 18.

Go to step 24.

Go to step 19.

Go to step 25.

Go to step 20.

Go to step 26.

Go to step 27.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

21

Step ONLY ONE CYLINDER.

Check Is there any fault in the cylinder?

22

GROUP OF #1 AND #2 CYLINDERS.

Are there any faults in #1 and #2 cylinders?

23

GROUP OF #3 AND #4 CYLINDERS.

Are there any faults in #3 and #4 cylinders?

EN(H6DO)(diag)-201

Yes Repair or replace faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio

No Check DTC P0171, P0172, P0174 or P0175 using “List of Diagnostic Trouble Code (DTC)”.

Repair or replace Check DTC faulty parts. P0171, P0172, P0174 or P0175 NOTE: • Check the fol- using “List of Diagnostic Trouble lowing items. Code (DTC)”. • Spark plug • Fuel injector found, check the “IGNITION CONTROL SYSTEM” of #1 and #2 cylinders side. Repair or replace Check DTC faulty parts. P0171, P0172, P0174 or P0175 NOTE: • Check the fol- using “List of Diagnostic Trouble lowing items. Code (DTC)”. • Spark plug • Fuel injector found, check the “IGNITION CONTROL SYSTEM” of #3 and #4 cylinders side.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

24

Step GROUP OF #5 AND #6 CYLINDERS.

25

GROUP OF #1, #3 AND #5 CYLINDERS.

26

GROUP OF #2, #4 AND #6 CYLINDERS.

27

CYLINDER AT RANDOM.

Check Are there any faults in #5 and #6 cylinders?

Yes Repair or replace faulty parts. NOTE: • Check the following items. • Spark plug • Fuel injector • Ignition coil • Compression ratio • If any fault is not found, check the “IGNITION CONTROL SYSTEM” of #5 and #6 cylinders side. Is there any fault in #1, #3 and Repair or replace #5 cylinders? faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio • Skipping timing chain teeth Is there any fault in #2, #4 and Repair or replace #6 cylinders? faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio • Skipping timing chain teeth Is the engine idle rough? Check DTC P0171, P0172, P0174 or P0175 using “List of Diagnostic Trouble Code (DTC)”.

EN(H6DO)(diag)-202

No Check DTC P0171, P0172, P0174 or P0175 using “List of Diagnostic Trouble Code (DTC)”.

Check DTC P0171, P0172, P0174 or P0175 using “List of Diagnostic Trouble Code (DTC)”.

Check DTC P0171, P0172, P0174 or P0175 using “List of Diagnostic Trouble Code (DTC)”.

Repair or replace faulty parts. NOTE: Check the following items. • Spark plug • Fuel injector • Compression ratio

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BT:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

E48

2

KNOCK SENSOR 1 (RH)

1

2

1

KNOCK SENSOR 2 (LH)

E14

4

1

6

E2

D8

D2

D4

A29

B21

ECM A : B134

D : B137

E

B21 E14

1 2

D : B137

A : B134

E48 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07578

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B137) No. 2 — (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor terminals. Terminals No. 1 — No. 2:

Check Is the resistance 600 kΩ or more?

Yes Go to step 2.

No Repair the poor contact of ECM connector.

Is the resistance 600 kΩ or more?

Replace the knock sensor.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and knock sensor connector • Poor contact of knock sensor connector • Poor contact of coupling connector

EN(H6DO)(diag)-204

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BU:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Poor driving performance • Knocking occurs. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

E48

2

KNOCK SENSOR 1 (RH)

1

2

1

KNOCK SENSOR 2 (LH)

E14

4

1

6

E2

D8

D2

D4

A29

B21

ECM A : B134

D : B137

E

B21 E14

1 2

D : B137

A : B134

E48 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07578

EN(H6DO)(diag)-205

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B137) No. 2 — (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor connectors. Terminals No. 1 — No. 2:

Check Yes Is the resistance less than 500 Go to step 2. kΩ?

CHECK INPUT SIGNAL OF ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 2 (+) — Chassis ground (–):

Is the voltage 2 V or more?

Is the resistance less than 500 Replace the knock kΩ? sensor.

EN(H6DO)(diag)-206

No Go to step 3.

Repair the ground short circuit of harness between ECM and knock sensor connector. NOTE: The harness between both connectors are shielded. Remove the shield and repair the short circuit of the harness. Even if DTC is Repair the poor detected, the cir- contact of ECM cuit has returned to connector. a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BV:DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Driving performance problem • Knocking is occurred. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

E48

2

KNOCK SENSOR 1 (RH)

1

2

1

KNOCK SENSOR 2 (LH)

E14

4

1

6

E2

D8

D2

D4

A29

B21

ECM A : B134

D : B137

E

B21 E14

1 2

D : B137

A : B134

E48 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07578

EN(H6DO)(diag)-207

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B137) No. 4 — (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor terminals. Terminals No. 1 — No. 2:

Check Is the resistance 600 kΩ or more?

Yes Go to step 2.

No Repair the poor contact of ECM connector.

Is the resistance 600 kΩ or more?

Replace the knock sensor.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and knock sensor connector • Poor contact of knock sensor connector • Poor contact of coupling connector

EN(H6DO)(diag)-208

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BW:DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Driving performance problem • Knocking occurs. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

E48

2

KNOCK SENSOR 1 (RH)

1

2

1

KNOCK SENSOR 2 (LH)

E14

4

1

6

E2

D8

D2

D4

A29

B21

ECM A : B134

D : B137

E

B21 E14

1 2

D : B137

A : B134

E48 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07578

EN(H6DO)(diag)-209

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK HARNESS BETWEEN ECM AND KNOCK SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B137) No. 4 — (B134) No. 29: CHECK KNOCK SENSOR. 1) Disconnect the connector from knock sensor. 2) Measure the resistance between knock sensor connectors. Terminals No. 1 — No. 2:

Check Yes Is the resistance less than 500 Go to step 2. kΩ?

CHECK INPUT SIGNAL OF ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 4 (+) — Chassis ground (–):

Is the voltage 2 V or more?

Is the resistance less than 500 Replace the knock kΩ? sensor.

EN(H6DO)(diag)-210

No Go to step 3.

Repair the ground short circuit of harness between ECM and knock sensor connector. NOTE: The harness between both connectors are shielded. Remove the shield and repair the short circuit of the harness. Even if DTC is Repair the poor detected, the cir- contact of ECM cuit has returned to connector. a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BX:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2

CRANKSHAFT POSITION SENSOR

E10

3 14

E2

31

17 25

B21

B137

ECM

E

B21 B137 E10

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07579

EN(H6DO)(diag)-211

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR. sor installation bolt tightened securely?

Yes Go to step 2.

CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 and 1) Turn the ignition switch to OFF. 4 kΩ? 2) Remove the crankshaft position sensor. 3) Measure the resistance between terminals of crankshaft position sensor connector. Terminals No. 1 — No. 2: CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? CRANKSHAFT POSITION SENSOR CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and crankshaft position sensor connector. Connector & terminal (B137) No. 17 — (E10) No. 1: (B137) No. 25 — (E10) No. 2:

Go to step 3.

EN(H6DO)(diag)-212

Repair the poor contact of ECM and crankshaft position sensor connector.

No Tighten the crankshaft position sensor installation bolt securely. Replace the crankshaft position sensor. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and crankshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BY:DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2 3

Step Check CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR. sor installation bolt tightened Turn the ignition switch to OFF. securely?

No Tighten the crankshaft position sensor installation bolt securely. CHECK CRANKSHAFT PLATE. Is there crack or damage in the Replace the crank- Go to step 3. crankshaft plate teeth? shaft plate. CHECK INSTALLATION CONDITION OF Is the timing chain dislocated Correct the instal- Replace the crankTIMING CHAIN. from its proper position? lation condition of shaft position senTurn the crankshaft, and align alignment mark timing chain. SOCKET

EN(H6DO)(diag)-213

Yes Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BZ:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY

B220 M/B No. 16 4 3

E35

3

1

INTAKE CAMSHAFT POSITION SENSOR RH

3

2

1

INTAKE CAMSHAFT POSITION SENSOR LH

2

1 2

E E36

2

13

5

48

E2

24

16

30

B21

B137

ECM

B21 E35

B220

E36

1 2 3

1 3 4 2

5 7 8 6

9 11 12 10

B137

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07773

EN(H6DO)(diag)-214

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E36) No. 1 (+) — Engine ground (–):

Yes Go to step 2.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and camshaft position sensor connector • Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and camshaft position sensor connector. Connector & terminal (B137) No. 24 — (E36) No. 2: (B137) No. 30 — (E36) No. 3:

3

CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E36) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E36) No. 2 (+) — Engine ground (–): CHECK CONDITION OF CAMSHAFT POSITION SENSOR.

Is the resistance 1 MΩ or more?

Go to step 4.

Is the voltage 5 V or more?

Repair the short Go to step 5. circuit to power in the harness between ECM and camshaft position sensor connector.

CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor.

Is there any abnormality in waveform?

4

5

6

Is the camshaft position sensor Go to step 6. installation bolt tightened securely?

EN(H6DO)(diag)-215

Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. camshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CA:DTC P0345 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY

B220 M/B No. 16 4 3

E35

3

1

INTAKE CAMSHAFT POSITION SENSOR RH

3

2

1

INTAKE CAMSHAFT POSITION SENSOR LH

2

1 2

E E36

2

13

5

48

E2

24

16

30

B21

B137

ECM

B21 E35

B220

E36

1 2 3

1 3 4 2

5 7 8 6

9 11 12 10

B137

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07773

EN(H6DO)(diag)-216

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E35) No. 1 (+) — Engine ground (–):

Yes Go to step 2.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and camshaft position sensor connector • Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and camshaft position sensor connector. Connector & terminal (B137) No. 16 — (E35) No. 2: (B137) No. 30 — (E35) No. 3:

3

CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E35) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E35) No. 2 (+) — Engine ground (–): CHECK CONDITION OF CAMSHAFT POSITION SENSOR.

Is the resistance 1 MΩ or more?

Go to step 4.

Is the voltage 5 V or more?

Repair the short Go to step 5. circuit to power in the harness between ECM and camshaft position sensor connector.

CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor.

Is there any abnormality in waveform?

4

5

6

Is the camshaft position sensor Go to step 6. installation bolt tightened securely?

EN(H6DO)(diag)-217

Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. camshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CB:DTC P0365 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY

B220 M/B No. 16 4 3

E65

3

1

EXHAUST CAMSHAFT POSITION SENSOR RH

3

2

1

EXHAUST CAMSHAFT POSITION SENSOR LH

2

1 2

E E62

15

26

5

48

E2

23

29

30

B21

B137

ECM

B21 E62

B220

E65

1 2 3

1 3 4 2

5 7 8 6

9 11 12 10

B137

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07774

EN(H6DO)(diag)-218

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E62) No. 1 (+) — Engine ground (–):

Yes Go to step 2.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and camshaft position sensor connector • Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and camshaft position sensor connector. Connector & terminal (B137) No. 23 — (E62) No. 2: (B137) No. 30 — (E62) No. 3:

3

CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E62) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E62) No. 2 (+) — Engine ground (–): CHECK CONDITION OF CAMSHAFT POSITION SENSOR.

Is the resistance 1 MΩ or more?

Go to step 4.

Is the voltage 5 V or more?

Repair the short Go to step 5. circuit to power in the harness between ECM and camshaft position sensor connector.

CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor.

Is there any abnormality in waveform?

4

5

6

Is the camshaft position sensor Go to step 6. installation bolt tightened securely?

EN(H6DO)(diag)-219

Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. camshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CC:DTC P0390 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Failure of engine to start CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

MAIN RELAY

BATTERY

B220 M/B No. 16 4 3

E65

3

1

EXHAUST CAMSHAFT POSITION SENSOR RH

3

2

1

EXHAUST CAMSHAFT POSITION SENSOR LH

2

1 2

E E62

15

26

5

48

E2

23

29

30

B21

B137

ECM

B21 E62

B220

E65

1 2 3

1 3 4 2

5 7 8 6

9 11 12 10

B137

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07774

EN(H6DO)(diag)-220

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check CHECK POWER SUPPLY OF CAMSHAFT Is the voltage 10 V or more? POSITION SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from camshaft position sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E65) No. 1 (+) — Engine ground (–):

Yes Go to step 2.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit or short circuit to ground in harness between main relay connector and camshaft position sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and camshaft position sensor connector • Poor contact of coupling connector Repair short circuit to ground in harness between ECM and camshaft position sensor connector.

2

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. CAMSHAFT POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and camshaft position sensor connector. Connector & terminal (B137) No. 29 — (E65) No. 2: (B137) No. 30 — (E65) No. 3:

3

CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the resistance between camshaft position sensor connector and engine ground. Connector & terminal (E65) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND CAMSHAFT POSITION SENSOR CONNECTOR. Measure the voltage between camshaft position sensor connector and engine ground. Connector & terminal (E65) No. 2 (+) — Engine ground (–): CHECK CONDITION OF CAMSHAFT POSITION SENSOR.

Is the resistance 1 MΩ or more?

Go to step 4.

Is the voltage 5 V or more?

Repair the short Go to step 5. circuit to power in the harness between ECM and camshaft position sensor connector.

CHECK CAMSHAFT POSITION SENSOR. Check the waveform of the camshaft position sensor.

Is there any abnormality in waveform?

4

5

6

Is the camshaft position sensor Go to step 6. installation bolt tightened securely?

EN(H6DO)(diag)-221

Tighten the camshaft position sensor installation bolt securely. Replace the cam- Repair the followshaft position sen- ing item. sor. camshaft position sensor connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CD:DTC P0400 EXHAUST GAS RECIRCULATION FLOW DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Movement performance problem when engine is low speed. • Improper idling • Movement performance problem CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2 ECM

8 9 20 30

E B134

48 8 19 29 30

B21 E2

10 4 3 7 6

E76

2 5 3 1 4 6

E77

E18

EGR VALVE

E18 B21

1 2 3 4 5 6

E77

B220

1 3 4 2

5 7 8 6

9 11 12 10

B134

13 15 16 14

17 18 20 21 19

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

1 2 3 4 5 6 7 9 10 8

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07775

EN(H6DO)(diag)-222

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK CURRENT DATA. 1) Start the engine. 2) Read data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK EGR VALVE. Remove the EGR valve.

Check Yes No Is the measured value 53.3 kPa Make sure that the Go to step 2. (400 mmHg, 15.75 inHg) or EGR valve, manimore? fold absolute pressure sensor and throttle body are installed securely.

Are there any holes, clogged lines or foreign matters in the EGR system?

EN(H6DO)(diag)-223

Repair the EGR system.

Replace the EGR valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CE:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine stalls. • Idle mixture is out of specifications. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

3

E25

2

2

9 10

REAR OXYGEN SENSOR RH

3

M/B No. 15 12 11

4

REAR OXYGEN SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E61

9

10

11

12

16

15

13

14

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

1 2 3 4 5 6 7 8

2 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-224

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK EXHAUST SYSTEM. Check for gas leaks or air suction caused by loose or dislocated nuts and bolts, and open hole at exhaust pipes. NOTE: Check the following positions. • Between cylinder head and front exhaust pipe • Between front exhaust pipe and front catalytic converter • Between front catalytic converter and rear catalytic converter • Loose or improperly attached front oxygen (A/F) sensor or rear oxygen sensor CHECK WAVEFORM DATA ON THE SUBARU SELECT MONITOR (WHILE DRIVING). 1) Drive at a constant speed of 80 — 112 km/h (50 — 70 MPH). 2) After 5 minutes have elapsed in the condition of step 1), use the Subaru Select Monitor while still driving to read the waveform data. • At normal condition

Check Is there any fault in exhaust system?

Yes No Repair or replace Go to step 2. the exhaust system.

Is a normal waveform displayed?

Even if DTC is Go to step 3. detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

1 REAR OXYGEN SENSOR VOLTAGE (V) 0 1.5 A/F SENSOR OUTPUT LAMBDA 1 0.5 10 sec/div

EN-06666

• At abnormal condition (numerous inversion) 1 REAR OXYGEN SENSOR VOLTAGE (V) 0 1.5 A/F SENSOR OUTPUT LAMBDA 1 0.5 10 sec/div

EN-06667

EN(H6DO)(diag)-225

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

Step Check CHECK WAVEFORM DATA ON THE SUBA- Is a normal waveform displayed? RU SELECT MONITOR (WHILE IDLING). 1) Run the engine at idle. 2) In the state of step 1), read the waveform data using the Subaru Select Monitor. • At normal condition

Yes Go to step 4.

1

No • The waveform is displayed at abnormal condition 1:Go to step 4. • The waveform is displayed at abnormal condition 2:Go to step 5.

REAR OXYGEN SENSOR VOLTAGE (V)

0 10 sec/div

EN-06668

• At abnormal condition 1 (numerous inversion) 1

REAR OXYGEN SENSOR VOLTAGE (V)

0 10 sec/div

EN-06669

• At abnormal condition 2 (noise input) 1

REAR OXYGEN SENSOR VOLTAGE (V)

0 10 sec/div

4

5

EN-06670

CHECK CATALYTIC CONVERTER.

Is the catalytic converter dam- Replace the cataaged? lytic converter.

CHECK REAR OXYGEN SENSOR CONNEC- Has water entered the connec- Completely TOR AND COUPLING CONNECTOR. tor? remove any water inside.

EN(H6DO)(diag)-226

Go to step 5.

Go to step 6.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 7. REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E61) No. 3: (B135) No. 30 — (E61) No. 4: (B135) No. 28 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

7

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E61) No. 3 (+) — Chassis ground (–): (E25) No. 3 (+) — Chassis ground (–):

Is the voltage 0.2 — 0.5 V?

8

CHECK REAR OXYGEN SENSOR SHIELD. 1) Turn the ignition switch to OFF. 2) Expose the rear oxygen sensor connector body side harness sensor shield. 3) Measure the resistance between sensor shield and chassis ground.

Is the resistance less than 1 Ω? Replace the rear oxygen sensor.

EN(H6DO)(diag)-227

Go to step 8.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Repair the harness and connector. NOTE: Repair the following locations. • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair the open circuit of rear oxygen sensor harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CF:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Fuel odor • There is a hole of more than 1.0 mm (0.04 in) dia. in evaporation system or fuel tank. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode .

2

Step Check CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 1) Turn the ignition switch to OFF. securely? 2) Check the fuel filler cap. NOTE: The DTC is stored in memory if fuel filler cap is or was loose or if the cap chain has caught while tightening. CHECK FUEL FILLER CAP. Is the fuel filler cap genuine?

3

CHECK FUEL FILLER PIPE GASKET.

4

CHECK DRAIN VALVE. 1) Install the delivery (test) mode fuse. 2) Turn the ignition switch to ON. 3) Operate the drain valve using the Subaru Select Monitor. NOTE: Drain valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”. CHECK PURGE CONTROL SOLENOID Does the purge control soleVALVE. noid valve operate? Operate the purge control solenoid valve using the Subaru Select Monitor. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

1

5

Yes Go to step 2.

No Tighten fuel filler cap securely.

Go to step 3.

Replace with a genuine fuel filler cap. Go to step 4.

Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe.

Does the drain valve operate? Go to step 5. Replace the drain valve.

EN(H6DO)(diag)-228

Go to step 6.

Replace the purge control solenoid valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

Step CHECK EVAPORATIVE EMISSION CONTROL SYSTEM LINE. 1) Turn the ignition switch to OFF. 2) Remove the delivery (test) mode fuse.

7

CHECK CANISTER.

8

CHECK FUEL TANK. Remove the fuel tank.

9

CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.

Check Yes Is there any hole of more than Repair or replace 1.0 mm (0.04 in) dia. on evapo- the evaporation ration line? line. Is the canister damaged or is Repair or replace there a hole of more than 1.0 the canister. Is the fuel tank damaged or is Repair or replace there any hole of more than 1.0 the fuel tank. Is there any hole of more than Repair or replace 1.0 mm (0.04 in) dia., crack, the hoses or pipes. clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system?

EN(H6DO)(diag)-229

No Go to step 7.

Go to step 8.

Go to step 9.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CG:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2 ECM

E 4

B135

1 15

B38 i3

10 9

i54

1 2

R99

R144

DRAIN VALVE

R144

1 2

i54 1 2 3 4 5 6 7 8 9 10 11 12 13

CANISTER

B220

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 3 4 2

5 7 8 6

9 11 12 10

B135

13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

EN-07780

EN(H6DO)(diag)-230

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 4 (+) — Chassis ground (–): CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is the voltage 10 V or more?

Yes Go to step 2.

No Go to step 3.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

CHECK POWER SUPPLY TO DRAIN VALVE. Measure the voltage between drain valve and chassis ground. Connector & terminal (R144) No. 1 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND DRAIN VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and drain valve. 3) Measure the resistance between the drain valve connector and chassis ground. Connector & terminal (R144) No. 2 — Chassis ground: CHECK HARNESS BETWEEN ECM AND DRAIN VALVE CONNECTOR. Measure the resistance of harness between ECM and drain valve connector. Connector & terminal (B135) No. 4 — (R144) No. 2:

Is the voltage 10 V or more?

Go to step 4.

Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary open or short circuit of harness or temporary poor contact of connector may be the cause. Repair the power supply circuit.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the ground short circuit of harness between ECM and drain valve connector.

Is the resistance less than 1 Ω? Go to step 6.

CHECK DRAIN VALVE. Measure the resistance between drain valve terminals. Terminals No. 1 — No. 2:

Is the resistance 10 — 100 Ω? Repair the poor contact of drain valve connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and drain valve connector • Poor contact of coupling connector Replace the drain valve.

EN(H6DO)(diag)-231

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CH:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2 ECM

E 4

B135

1 15

B38 i3

10 9

i54

1 2

R99

R144

DRAIN VALVE

R144

1 2

i54 1 2 3 4 5 6 7 8 9 10 11 12 13

CANISTER

B220

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 3 4 2

5 7 8 6

9 11 12 10

B135

13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

EN-07780

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? DRAIN VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and drain valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 4 (+) — Chassis ground (–): Is the resistance less than 1 Ω? CHECK DRAIN VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between drain valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-233

Yes No Repair the short Go to step 2. circuit to power in the harness between ECM and drain valve connector.

Replace the drain valve.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CI: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

Step CHECK FUEL FILLER CAP. 1) Turn the ignition switch to OFF. 2) Open the fuel flap. CHECK PRESSURE VACUUM LINE. NOTE: Check the following items. • Disconnection, leakage and clogging of the vacuum hoses and pipes between fuel tank pressure sensor and fuel tank • Disconnection, leakage and clogging of air ventilation hoses and pipes between fuel filler pipe and fuel tank

Check Is the fuel filler cap tightened securely?

Yes Go to step 2.

No Tighten fuel filler cap securely.

Is there any fault in pressure/ vacuum line?

Repair or replace the hoses and pipes.

Replace the fuel tank pressure sensor.

EN(H6DO)(diag)-234

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CJ:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

3 10

2 8

9

1

FUEL TANK PRESSURE SENSOR

R47

R57 R15

10

11

9

6

12

2

R333 i155

i3 B83

B22

C21

* * B30

J/C

B38

B : B135 ECM

*

C : B136

R47

B83

1 2 3

1 2 3 4 5 6 7 8

i155 1 3

R57

2 4 5 6 7 8 9 10 11

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B : B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

: TERMINAL No. OPTIONAL ARRANGEMENT

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07781

EN(H6DO)(diag)-235

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

Step Check Yes CHECK CURRENT DATA. Is the measured value less than Go to step 2. 1) Turn the ignition switch to ON. –7.45 kPa (–55.85 mmHg, – 2) Read the data of fuel tank pressure sensor 2.2003 inHg)? signal using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

2

CHECK FUEL TANK PRESSURE SENSOR Is the voltage 4.5 V or more? POWER SUPPLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Measure the voltage between the fuel tank pressure sensor connector and chassis ground. Connector & terminal (R47) No. 3 (+) — Chassis ground (–):

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between the ECM and fuel tank pressure sensor connector. Connector & terminal (B136) No. 21 — (R47) No. 2:

4

CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 21 — Chassis ground: CHECK FOR POOR CONTACT. Check for poor contact between the ECM and fuel tank pressure sensor connector.

5

Is the resistance 1 MΩ or more?

Go to step 3.

Go to step 5.

Is there poor contact of the Repair the poor ECM or fuel tank pressure sen- contact of the ECM sor connector? or fuel tank pressure sensor connector.

EN(H6DO)(diag)-236

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and fuel tank pressure sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and fuel tank pressure sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and fuel tank pressure sensor connector. Replace the fuel tank pressure sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CK:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

3 10

2 8

9

1

FUEL TANK PRESSURE SENSOR

R47

R57 R15

10

11

9

6

12

2

R333 i155

i3 B83

B22

C21

* * B30

J/C

B38

B : B135 ECM

*

C : B136

R47

B83

1 2 3

1 2 3 4 5 6 7 8

i155 1 3

R57

2 4 5 6 7 8 9 10 11

B38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

B : B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

: TERMINAL No. OPTIONAL ARRANGEMENT

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07781

EN(H6DO)(diag)-237

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK CURRENT DATA. Is the measured value 7.98 kPa Go to step 2. 1) Turn the ignition switch to ON. (59.85 mmHg, 2.357 inHg) or 2) Read the data of fuel tank pressure sensor more? signal using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the fuel tank pressure sensor. 3) Turn the ignition switch to ON. 4) Read the data of fuel tank pressure sensor signal using the Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND FUEL TANK PRESSURE SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance of harness between fuel tank pressure sensor connector and engine ground. Connector & terminal (R47) No. 1 — Engine ground:

Is the measured value 7.98 kPa Repair the short (59.85 mmHg, 2.357 inHg) or circuit to power in more? the harness between ECM and fuel tank pressure sensor connector.

Is the resistance less than 5 Ω? Go to step 4.

CHECK FOR POOR CONTACT. Is there poor contact of fuel Check for poor contact of the fuel tank pressure tank pressure sensor connecsensor connector. tor?

EN(H6DO)(diag)-238

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause. Go to step 3.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and fuel tank pressure sensor connector • Poor contact of ECM connector • Poor contact of coupling connector Repair the poor Replace the fuel contact of fuel tank tank pressure senpressure sensor sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CL:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Fuel odor • There is a hole of more than 0.5 mm (0.020 in) dia. in evaporation system or fuel tank. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode .

2

Step Check CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 1) Turn the ignition switch to OFF. securely? 2) Check the fuel filler cap. NOTE: The DTC is stored in memory if fuel filler cap is or was loose or if the cap chain has caught while tightening. CHECK FUEL FILLER CAP. Is the fuel filler cap genuine?

3

CHECK FUEL FILLER PIPE GASKET.

4

CHECK DRAIN VALVE. 1) Install the delivery (test) mode fuse. 2) Turn the ignition switch to ON. 3) Operate the drain valve using the Subaru Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK PURGE CONTROL SOLENOID Does the purge control soleVALVE. noid valve operate? Operate the purge control solenoid valve using the Subaru Select Monitor. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

1

5

Yes Go to step 2.

No Tighten fuel filler cap securely.

Go to step 3.

Replace with a genuine fuel filler cap. Go to step 4.

Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe.

Does the drain valve operate? Go to step 5. Replace the drain valve.

EN(H6DO)(diag)-239

Go to step 6.

Replace the purge control solenoid valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

Step CHECK EVAPORATIVE EMISSION CONTROL SYSTEM LINE. 1) Turn the ignition switch to OFF. 2) Remove the delivery (test) mode fuse.

7

CHECK CANISTER.

8

CHECK FUEL TANK. Remove the fuel tank.

9

CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.

Check Yes Is there any hole of more than Repair or replace 0.5 mm (0.020 in) dia. on evap- the evaporation oration line? line. Is the canister damaged or is Repair or replace there a hole of more than 0.5 the canister. Is the fuel tank damaged or is Repair or replace there any hole of more than 0.5 the fuel tank. Is there any hole of more than Repair or replace 0.5 mm (0.020 in) dia., crack, the hoses or pipes. clogging, or disconnections, bend, misconnection of hoses or pipes in evaporative emission control system?

EN(H6DO)(diag)-240

No Go to step 7.

Go to step 8.

Go to step 9.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CM:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Fuel odor • Fuel filler cap loose or lost CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode .

2

Step Check CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 1) Turn the ignition switch to OFF. securely? 2) Check the fuel filler cap. NOTE: The DTC is stored in memory if fuel filler cap is or was loose or if the cap chain has caught while tightening. CHECK FUEL FILLER CAP. Is the fuel filler cap genuine?

3

CHECK FUEL FILLER PIPE GASKET.

4

CHECK DRAIN VALVE. 1) Install the delivery (test) mode fuse. 2) Turn the ignition switch to ON. 3) Operate the drain valve using the Subaru Select Monitor. NOTE: Drain valve can be operated using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

CHECK PURGE CONTROL SOLENOID Does the purge control soleVALVE. noid valve operate? Operate the purge control solenoid valve using the Subaru Select Monitor. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

1

5

Yes Go to step 2.

No Tighten fuel filler cap securely.

Go to step 3.

Replace with a genuine fuel filler cap. Go to step 4.

Is there any damage to the seal Repair or replace between fuel filler cap and fuel the fuel filler cap filler pipe? and fuel filler pipe.

Does the drain valve operate? Go to step 5. Replace the drain valve.

EN(H6DO)(diag)-241

Go to step 6.

Replace the purge control solenoid valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) Step CHECK EVAPORATIVE EMISSION CONTROL SYSTEM LINE. 1) Turn the ignition switch to OFF. 2) Remove the delivery (test) mode fuse.

Check Is there any disconnection, damage or clogging on the evaporation line?

7

CHECK CANISTER.

Is the canister damaged?

8

CHECK FUEL TANK. Remove the fuel tank.

Is the fuel tank damaged?

9

CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.

Are there holes, cracks, clogging, or disconnections, misconnection of hoses or pipes in evaporative emission control system?

6

EN(H6DO)(diag)-242

Yes Repair or replace the evaporation line. Repair or replace the canister. Repair or replace the fuel tank. Repair or replace the hoses or pipes.

No Go to step 7.

Go to step 8.

Go to step 9.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CN:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2 ECM

E 6

B137

48 11

B21 E2

10 2

E76

1 2

E77

E4

PURGE CONTROL SOLENOID VALVE

E4 B21 1 2

E77

B220

1 3 4 2

5 7 8 6

9 11 12 10

B137

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

1 2 3 4 5 6 7 9 10 8

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07776

EN(H6DO)(diag)-243

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 6 (+) — Chassis ground (–): CHECK FOR POOR CONTACT. Check for poor contact of ECM connector.

Check Is the voltage 10 V or more?

Yes Go to step 2.

No Go to step 3.

Is there poor contact of ECM connector?

Repair the poor contact of ECM connector.

CHECK POWER SUPPLY TO PURGE CONTROL SOLENOID VALVE. Measure the voltage between purge control solenoid valve and engine ground. Connector & terminal (E4) No. 1 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Measure the resistance between the purge control solenoid valve connector and engine ground. Connector & terminal (E4) No. 2 — Engine ground: CHECK HARNESS BETWEEN ECM AND PURGE CONTROL SOLENOID VALVE CONNECTOR. Measure the resistance of harness between ECM and purge control solenoid valve. Connector & terminal (B137) No. 6 — (E4) No. 2:

Is the voltage 10 V or more?

Go to step 4.

Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary open or short circuit of harness or temporary poor contact of connector may be the cause. Repair the power supply circuit.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the ground short circuit of harness between ECM and purge control solenoid valve connector.

Is the resistance less than 1 Ω? Go to step 6.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and purge control solenoid valve connector • Poor contact of coupling connector Replace the purge control solenoid valve.

CHECK PURGE CONTROL SOLENOID Is the resistance 10 — 100 Ω? VALVE. 1) Remove the purge control solenoid valve. 2) Measure the resistance between purge control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-244

Repair the poor contact of purge control solenoid valve connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CO:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2 ECM

E 6

B137

48 11

B21 E2

10 2

E76

1 2

E77

E4

PURGE CONTROL SOLENOID VALVE

E4 B21 1 2

E77

B220

1 3 4 2

5 7 8 6

9 11 12 10

B137

13 15 16 14

17 18 20 21 19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

1 2 3 4 5 6 7 9 10 8

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07776

EN(H6DO)(diag)-245

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? PURGE CONTROL SOLENOID VALVE. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and purge control solenoid valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B137) No. 6 (+) — Chassis ground (–): CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 Ω? VALVE. 1) Turn the ignition switch to OFF. 2) Measure the resistance between purge control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-246

Yes No Repair the short Go to step 2. circuit of harness to power supply between ECM and purge control solenoid valve connector.

Replace the purge Repair the poor control solenoid contact of ECM valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CP:DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Replace the fuel level sensor and fuel sub level sensor.

CQ:DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW NOTE: For the diagnostic procedure, refer to DTC P0463.

CR:DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0462 or P0463 displayed on the Subaru Select Monitor?

EN(H6DO)(diag)-247

Yes Check the combination meter.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CS:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check Yes CHECK FOR ANY OTHER DTC ON DISPLAY. Is DTC P0464 displayed on the Check the combidisplay? nation meter.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

CT:DTC P0500 VEHICLE SPEED SENSOR “A” DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step CHECK DTC OF VDC. Check DTC of VDC.

Check Is DTC of VDC displayed?

EN(H6DO)(diag)-248

Yes No Perform the diag- Repair the poor nosis according to contact of ECM DTC.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CU:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Hard to start the engine. • Engine does not start. • Improper idling • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

No Go to step 2.

2

CHECK AIR CLEANER ELEMENT. 1) Turn the ignition switch to OFF. 2) Check the air cleaner element.

Go to step 3.

3

CHECK ELECTRONIC THROTTLE CONTROL. 1) Remove the electronic throttle control. 2) Check the electronic throttle control.

1

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Is there excessive clogging on Replace the air air cleaner element? cleaner element.

Are foreign matter found inside Remove foreign electronic throttle control? matter from electronic throttle control.

EN(H6DO)(diag)-249

Perform the diagnosis of DTC P2101.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CV:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: Engine keeps running at higher speed than specified idle speed. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2

3

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK AIR INTAKE SYSTEM. 1) Start and idle the engine. 2) Check the following items. • Loose installation of intake manifold and throttle body • Cracks of intake manifold gasket and throttle body gasket • Disconnection of vacuum hoses CHECK ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control. 3) Check the electronic throttle control.

Is there any fault in air intake system?

Yes No Check the appro- Go to step 2. priate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Repair air suction Go to step 3. and leaks.

Are foreign matter found inside Remove foreign electronic throttle control? matter from electronic throttle control.

EN(H6DO)(diag)-250

Perform the diagnosis of DTC P2101.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CW:DTC P0512 STARTER REQUEST CIRCUIT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

6

BATTERY SBF-5

MAIN SBF

3

2 IGNITION SWITCH

B72

E

4

2

4

2

F/B No. 21

B498

3

1

3

1

STARTER RELAY

B14

B54 TCM

STARTER MOTOR

B493

INHIBITOR RELAY

C16

B26

C35

11

ECM B : B135

C : B136

B54 B493

B498

1 2 3 4

B72 1 2 3 4 5 6

B : B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07764

EN(H6DO)(diag)-251

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK HARNESS BETWEEN ECM AND STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 16 (+) — Chassis ground (–):

Is the voltage 10 V or more?

EN(H6DO)(diag)-252

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Repair the short circuit to power supply in harness between ECM and starter relay connector.

No Go to step 2.

Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CX:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine does not start. • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

No Even if DTC is detected, the circuit has returned to a normal condition at this time. Reproduce the failure, and then perform the diagnosis again. NOTE: In this case, temporary poor contact of connector, temporary open or short circuit of harness may be the cause.

CY:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR NOTE: For the diagnostic procedure, refer to DTC P0607.

EN(H6DO)(diag)-253

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

CZ:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

B220 M/B No. 16 4 3 M/B No. 12 1 2 B72

IGNITION SWITCH SBF-5

F/B No. 12

MAIN SBF

3

C2 C30

B13 C1 D7

1

ECM BATTERY

D : B137 C4

A28 A18

C : B136 A19 A1 A2 A29

B : B135

A3 D5 D3 D1 A4 A6

A : B134

B138

* *

24 25

28 39 38 6

35 37 34 40 36

B21

J/C

E

E57

1 2 3 4 5 6

B72

B138

1 2 3 4 5 6

1 2 3 4 5 6 7 8

5 7 8 6

9 11 12 10

E57

*

ELECTRONIC THROTTLE CONTROL

A : B134 1 2 8 9 10 18 19 20 28 29 30

13 15 16 14

17 18 20 21 19

E

B : B135

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

: TERMINAL No. OPTIONAL ARRANGEMENT

E

C : B136

B220

1 3 4 2

4 6

5 1 2 3

E2

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07778

EN(H6DO)(diag)-254

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK INPUT VOLTAGE OF ECM. Is the voltage 10 — 13 V? Go to step 2. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 1 (+) — Chassis ground (–): (B137) No. 7 (+) — Chassis ground (–): CHECK INPUT VOLTAGE OF ECM. Is the voltage 13 — 15 V? Go to step 3. 1) Start the engine. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 1 (+) — Chassis ground (–): (B137) No. 7 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 19 — (E57) No. 5: (B134) No. 29 — (E57) No. 3:

CHECK ECM GROUND HARNESS. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 3 (+) — Chassis ground (–): (B134) No. 4 (+) — Chassis ground (–): (B134) No. 6 (+) — Chassis ground (–): (B137) No. 1 (+) — Chassis ground (–): (B137) No. 3 (+) — Chassis ground (–): (B137) No. 5 (+) — Chassis ground (–):

Is the voltage less than 1 V?

Repair the poor contact of ECM connector.

No Repair the open or ground short circuit of power supply circuit.

Repair the open or ground short circuit of power supply circuit.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in ground circuit • Retightening of engine ground terminals • Poor contact of coupling connector

DA:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1) NOTE: For the diagnostic procedure, refer to DTC P2101.

DB:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST) NOTE: For the diagnostic procedure, refer to AT section.

EN(H6DO)(diag)-255

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DC:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

B22

B503 1 2 3 4 5 6 7 8

1 2 3 4

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H6DO)(diag)-256

38 45 51

39 52

40 46 53

41 47 54

EN-07769

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 19 — (E47) No. 3: (B136) No. 18 — (E47) No. 4: CHECK FOR POOR CONTACT. Is there poor contact of front Check for poor contact of the front oxygen (A/F) oxygen (A/F) sensor connecsensor connector. tor?

EN(H6DO)(diag)-257

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the poor Replace the front contact of front oxygen (A/F) senoxygen (A/F) sen- sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DD:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

B22

B503 1 2 3 4 5 6 7 8

1 2 3 4

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H6DO)(diag)-258

38 45 51

39 52

40 46 53

41 47 54

EN-07769

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

4

5

Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 19 — Chassis ground: (B136) No. 18 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 19 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 18 (+) — Chassis ground (–):

Check Is the resistance 1 MΩ or more?

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

Is the voltage 4.5 V or more?

Go to step 5.

Go to step 4.

Is the voltage 4.95 V or more? Go to step 5.

Is the voltage 8 V or more? CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 19 (+) — Chassis ground (–): (B136) No. 18 (+) — Chassis ground (–):

EN(H6DO)(diag)-259

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Replace the front oxygen (A/F) sensor. Repair the poor contact of ECM connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DE:DTC P1154 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 2 SENSOR 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

B22

B503 1 2 3 4 5 6 7 8

1 2 3 4

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H6DO)(diag)-260

38 45 51

39 52

40 46 53

41 47 54

EN-07769

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 8 — (E24) No. 3: (B135) No. 20 — (E24) No. 4: CHECK FOR POOR CONTACT. Is there poor contact of front Check for poor contact of the front oxygen (A/F) oxygen (A/F) sensor connecsensor connector. tor?

EN(H6DO)(diag)-261

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the poor Replace the front contact of front oxygen (A/F) senoxygen (A/F) sen- sor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DF:DTC P1155 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 2 SENSOR 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

B22

B503 1 2 3 4 5 6 7 8

1 2 3 4

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

Step CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

Check Yes Has water entered the connec- Completely tor? remove any water inside.

EN(H6DO)(diag)-262

38 45 51

39 52

40 46 53

41 47 54

EN-07769

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

4

5

Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 8 — Chassis ground: (B135) No. 20 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 8 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 20 (+) — Chassis ground (–):

Check Is the resistance 1 MΩ or more?

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

Is the voltage 4.5 V or more?

Go to step 5.

Go to step 4.

Is the voltage 4.95 V or more? Go to step 5.

Is the voltage 8 V or more? CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between ECM and chassis ground. Connector & terminal (B135) No. 8 (+) — Chassis ground (–): (B135) No. 20 (+) — Chassis ground (–):

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Replace the front oxygen (A/F) sensor. Repair the poor contact of ECM connector.

DG:DTC P1160 RETURN SPRING FAILURE NOTE: For the diagnostic procedure, refer to DTC P2101.

EN(H6DO)(diag)-263

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DH:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper fuel supply CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

2 3

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK DRAIN HOSE. Is there clogging in the drain Check the drain hose for clogging. hose? CHECK DRAIN VALVE OPERATION. Does the drain valve operate? 1) Turn the ignition switch to OFF. 2) Install the delivery (test) mode fuse. 3) Turn the ignition switch to ON. 4) Operate the drain valve. NOTE: Drain valve can be operated using the Subaru Select Monitor. For detailed procedures, refer to “SYSTEM OPERATION CHECK MODE”.

EN(H6DO)(diag)-264

Yes Check the appropriate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Replace the drain hose. Repair the poor contact of ECM connector.

No Go to step 2.

Go to step 3. Replace the drain valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DI: DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) NOTE: For the diagnostic procedure, refer to DTC P1498.

DJ:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT) NOTE: For the diagnostic procedure, refer to DTC P1499.

DK:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT) NOTE: For the diagnostic procedure, refer to DTC P1498.

DL:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT) NOTE: For the diagnostic procedure, refer to DTC P1499.

DM:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT) NOTE: For the diagnostic procedure, refer to DTC P1498.

DN:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT) NOTE: For the diagnostic procedure, refer to DTC P1499.

EN(H6DO)(diag)-265

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DO:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine breathing CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode .

EN(H6DO)(diag)-266

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

WIRING DIAGRAM: MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2 ECM

8 9 20 30

E B134

48 8 19 29 30

B21 E2

10 4 3 7 6

E76

2 5 3 1 4 6

E77

E18

EGR VALVE

E18 B21

1 2 3 4 5 6

E77

B220

1 3 4 2

5 7 8 6

9 11 12 10

B134

13 15 16 14

17 18 20 21 19

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

1 2 3 4 5 6 7 8 9 10

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07775

1

Step Check CHECK POWER SUPPLY TO EGR VALVE. Is the voltage 10 V or more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from EGR valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between EGR valve connector and engine ground. Connector & terminal (E18) No. 2 (+) — Engine ground (–): (E18) No. 5 (+) — Engine ground (–):

EN(H6DO)(diag)-267

Yes Go to step 2.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between EGR valve connector and main relay connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 3. EGR VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance of harness between ECM and EGR valve connector. Connector & terminal DTC P1492; (B134) No. 8 — (E18) No. 3: DTC P1494; (B134) No. 9 — (E18) No. 1: DTC P1496; (B134) No. 20 — (E18) No. 4: DTC P1498; (B134) No. 30 — (E18) No. 6: CHECK HARNESS BETWEEN ECM AND EGR VALVE CONNECTOR. 1) Disconnect the connector from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal DTC P1492; (B134) No. 8 — Chassis ground: DTC P1494; (B134) No. 9 — Chassis ground: DTC P1496; (B134) No. 20 — Chassis ground: DTC P1498; (B134) No. 30 — Chassis ground: CHECK FOR POOR CONTACT. Check poor contact of ECM and EGR valve connectors.

Is the resistance 1 MΩ or more?

Go to step 4.

Is there poor contact of ECM or Repair the poor EGR valve connector? contact of ECM or EGR valve connector.

EN(H6DO)(diag)-268

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and EGR valve connector • Poor contact of coupling connector Repair the ground short in harness between ECM and EGR valve connector.

Replace the EGR valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DP:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine breathing CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode .

EN(H6DO)(diag)-269

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

WIRING DIAGRAM: MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2 ECM

8 9 20 30

E B134

48 8 19 29 30

B21 E2

10 4 3 7 6

E76

2 5 3 1 4 6

E77

E18

EGR VALVE

E18 B21

1 2 3 4 5 6

E77

B220

1 3 4 2

5 7 8 6

9 11 12 10

B134

13 15 16 14

17 18 20 21 19

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

1 2 3 4 5 6 7 8 9 10

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07775

1

Step Check CHECK HARNESS BETWEEN ECM AND Is the voltage 10 V or more? EGR VALVE CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and EGR valve. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground. Connector & terminal DTC P1493; (B134) No. 8 (+) — Chassis ground (–): DTC P1495; (B134) No. 9 (+) — Chassis ground (–): DTC P1497; (B134) No. 20 (+) — Chassis ground (–): DTC P1499; (B134) No. 30 (+) — Chassis ground (–):

EN(H6DO)(diag)-270

Yes No Repair the short Go to step 2. circuit to power in the harness between the ECM and EGR valve connectors.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

Step CHECK EGR VALVE. Measure the resistance between EGR valve terminals. Terminals DTC P1493; No. 2 — No. 3: DTC P1493; No. 5 — No. 3: DTC P1495; No. 2 — No. 1: DTC P1495; No. 5 — No. 1: DTC P1497; No. 2 — No. 4: DTC P1497; No. 5 — No. 4: DTC P1499; No. 2 — No. 6: DTC P1499; No. 5 — No. 6:

Check Yes Is the resistance 20 Ω or more? Repair the poor contact of ECM connector.

EN(H6DO)(diag)-271

No Replace the EGR valve.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DQ:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Failure of engine to start CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

6

BATTERY SBF-5

MAIN SBF

3

2 IGNITION SWITCH

B72

E

4

2

4

2

F/B No. 21

B498

3

1

3

1

STARTER RELAY

B14

B54 TCM

STARTER MOTOR

B493

INHIBITOR RELAY

C16

B26

C35

11

ECM B : B135

C : B136

B54 B493

B498

1 2 3 4

B72 1 2 3 4 5 6

B : B135 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

C : B136 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

EN-07764

EN(H6DO)(diag)-272

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. Is the resistance less than 1 Ω? Go to step 3. Repair the open circuit of harness between ECM and starter relay connector.

CHECK HARNESS BETWEEN ECM AND STARTER RELAY CONNECTOR. 1) Turn the ignition switch to OFF. 2) Remove the starter relay. 3) Disconnect the connectors from ECM and starter motor. 4) Measure the resistance of harness between ECM and starter relay connector. Connector & terminal (B136) No. 16 — (B493) No. 3: Is the resistance 1 MΩ or CHECK HARNESS BETWEEN ECM AND more? STARTER RELAY CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 16 — Chassis ground:

EN(H6DO)(diag)-273

Repair the poor contact of ECM connector.

Repair the short circuit to ground in harness between ECM and starter relay connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DR:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

B220

M/B No. 16

4 3 M/B No. 12 1 2 B72

IGNITION SWITCH

F/B No. 12

SBF-5

MAIN SBF

3

C2 C30

B13 C1 D7

1

A : B134 B : B135 ECM C : B136 BATTERY

A3 D5 D3 D1 A4 A6

D : B137

35 37 34 40 36

B21 E2

E

E

A : B134

B : B135

B72 1 2 8 9 10 18 19 20 28 29 30

1 2 3 4 5 6

C : B136

B220

1 3 4 2

5 7 8 6

9 11 12 10

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07765

1

Step CHECK INPUT SIGNAL OF ECM. 1) Turn the ignition switch to OFF. 2) Measure the voltage between ECM and chassis ground. Connector & terminal (B136) No. 2 (+) — Chassis ground (–):

Check Is the voltage 10 V or more?

EN(H6DO)(diag)-274

Yes Repair the poor contact of ECM connector.

No Go to step 2.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

2

3

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or MAIN FUSE BOX CONNECTOR. more? 1) Disconnect the connector from ECM. 2) Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 2 — Chassis ground: CHECK M/B FUSE NO. 12. Is the fuse blown out?

EN(H6DO)(diag)-275

Yes Go to step 3.

No Repair the ground short circuit of harness between ECM and battery terminal.

Replace the fuse.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and battery • Poor contact of ECM connector • Poor contact of battery terminal

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DS:DTC P1602 CONTROL MODULE PROGRAMMING ERROR DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Engine keeps running at higher speed than specified idle speed. • Engine keeps running at a lower speed than the specified idle speed. • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: MAIN RELAY

BATTERY

B220 M/B No. 16 4 3 1 2

24

23

13

12

11

10

ECM

B134

46

47

51

52

53

54

48

B21

FUEL INJECTOR No. 4

FUEL INJECTOR No. 6

FUEL INJECTOR No. 5

E6

E17 E44

1 2

E

B21

E16

E43

E44

1

E43

2

1

E17

2

1

E6

2

1

2

FUEL INJECTOR No. 3

FUEL INJECTOR No. 2

FUEL INJECTOR No. 1

E5

E16

1

E5

2

1

2

E2

B220

1 3 4 2

5 7 8 6

9 11 12 10

B134

13 15 16 14

17 18 20 21 19

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07768

EN(H6DO)(diag)-276

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS) ELECTRONIC THROTTLE CONTROL RELAY BATTERY

B220 M/B No. 13 16 15 M/B No. 16 13 14

B7

B17

MAIN RELAY

ECM

C4

D : B137 A28 A18

C : B136 A19 A1 A2 A29

B : B135

A3 D5 D3 D1 A4 A6

A : B134

B138

* *

24 25

28 39 38 6

35 37 34 40 36

B21

E

J/C

ELECTRONIC THROTTLE CONTROL

E

1 2 3 4 5 6 7 8

1 2 3 4 5 6

B220

1 3 4 2

5 7 8 6

A : B134

B138

E57

9 11 12 10

4 6

5 1 2 3

E2

1 2 8 9 10 18 19 20 28 29 30

13 15 16 14

*

E

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

17 18 20 21 19

E57

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07772

1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

2

CHECK ENGINE OIL.

Is there a proper amount of engine oil?

3

CHECK EXHAUST SYSTEM.

Are there holes or loose bolts on exhaust system?

EN(H6DO)(diag)-277

Yes No Check the appro- Go to step 2. priate DTC using the “List of Diagnostic Trouble Code (DTC)”.

Go to step 3. Replace engine oil.

Repair the exhaust Go to step 4. system.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

4

5

6

7

Step CHECK AIR INTAKE SYSTEM.

Check Yes Are there holes, loose bolts or Repair the air disconnection of hose on air intake system. intake system? CHECK FUEL PRESSURE. Is the measured value 333 — Go to step 6. 363 kPa (3.4 — 3.7 kgf/cm2, 48 WARNING: Place “NO OPEN FLAMES” signs near the — 53 psi)? working area. CAUTION: Be careful not to spill fuel. Measure the fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE Is the temperature 75°C Go to step 7. SENSOR. (167°F) or more? 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR Is the measured value 2.0 — Go to step 8. TEMPERATURE SENSOR. 5.0 g/s (0.26 — 0.66 lb/m)? 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

EN(H6DO)(diag)-278

No Go to step 5.

Repair the following item. Fuel pressure is too high: • Clogged fuel line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel line Replace the engine coolant temperature sensor.

Replace the mass air flow and intake air temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

8

9

10

11

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK OUTPUT SIGNAL OF ECM. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–): #5 (B134) No. 23 (+) — Chassis ground (–): #6 (B134) No. 24 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Measure the resistance between fuel injector connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 — Engine ground: #2 (E16) No. 1 — Engine ground: #3 (E6) No. 1 — Engine ground: #4 (E17) No. 1 — Engine ground: #5 (E43) No. 1 — Engine ground: #6 (E44) No. 1 — Engine ground: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. Measure the resistance of harness between ECM and fuel injector on faulty cylinders. Connector & terminal #1 (B134) No. 10 — (E5) No. 1: #2 (B134) No. 11 — (E16) No. 1: #3 (B134) No. 12 — (E6) No. 1: #4 (B134) No. 13 — (E17) No. 1: #5 (B134) No. 23 — (E43) No. 1: #6 (B134) No. 24 — (E44) No. 1:

Check Yes Subtract ambient temperature Go to step 9. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

No Check the mass air flow and intake air temperature sensor.

Is the voltage 10 V or more?

Go to step 14.

Go to step 10.

Is the resistance 1 MΩ or more?

Go to step 11.

Repair the ground short circuit of harness between ECM and fuel injector.

Is the resistance less than 1 Ω? Go to step 12.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and fuel injector connector • Poor contact of coupling connector

EN(H6DO)(diag)-279

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

12

13

14

15

16

Step CHECK FUEL INJECTOR. Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK POWER SUPPLY LINE. 1) Turn the ignition switch to ON. 2) Measure the voltage between fuel injector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 2 (+) — Engine ground (–): #2 (E16) No. 2 (+) — Engine ground (–): #3 (E6) No. 2 (+) — Engine ground (–): #4 (E17) No. 2 (+) — Engine ground (–): #5 (E43) No. 2 (+) — Engine ground (–): #6 (E44) No. 2 (+) — Engine ground (–):

Check Is the resistance 5 — 20 Ω?

Yes Go to step 13.

No Replace the faulty fuel injector.

Is the voltage 10 V or more?

Repair the poor contact of all connectors in fuel injector circuit.

CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from fuel injector on faulty cylinders. 3) Turn the ignition switch to ON. 4) Measure the voltage between ECM and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 10 (+) — Chassis ground (–): #2 (B134) No. 11 (+) — Chassis ground (–): #3 (B134) No. 12 (+) — Chassis ground (–): #4 (B134) No. 13 (+) — Chassis ground (–): #5 (B134) No. 23 (+) — Chassis ground (–): #6 (B134) No. 24 (+) — Chassis ground (–): CHECK FUEL INJECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 — No. 2: CHECK INSTALLATION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR.

Is the voltage 10 V or more?

Repair the short circuit to power in the harness between the ECM and fuel injector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between the main relay and fuel injector on faulty cylinders • Poor contact of coupling connector • Poor contact of main relay connector Go to step 15.

Is the resistance 5 — 20 Ω?

Replace the faulty Go to step 16. fuel injector.

17

CHECK CRANK PLATE.

18

CHECK INSTALLATION CONDITION OF TIMING CHAIN. Turn the crankshaft using ST, and align the alignment mark on crank sprocket with alignment mark on cylinder block. ST 18252AA000 CRANKSHAFT SOCKET

Is the camshaft position sensor Tighten the cam- Go to step 17. or crankshaft position sensor shaft position senloosely installed? sor or crankshaft position sensor. Is the crank sprocket rusted or Replace the crank Go to step 18. the teeth of crank plate broken? plate. Is the timing chain dislocated Correct the instal- Go to step 19. from its proper position? lation condition of timing chain.

EN(H6DO)(diag)-280

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

19

20

21

22

23

24

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 13 and No. 14 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 15 — No. 16: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connector from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 — Chassis ground: (B220) No. 15 — Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B135) No. 17 — (B220) No. 14: (B135) No. 7 — (B220) No. 15: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: (B134) No. 28 — Chassis ground:

Check Yes Is the resistance less than 1 Ω? Go to step 20.

No Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Go to step 21.

Repair the open or ground short circuit of power supply circuit.

Is the voltage 10 V or more?

Repair the short Go to step 22. circuit to power in harness between ECM and electronic throttle control relay.

Is the resistance 1 MΩ or more?

Go to step 23.

Repair the ground short circuit of harness between ECM and electronic throttle control relay.

Is the resistance less than 1 Ω? Go to step 24.

Repair the open circuit of harness between ECM and electronic throttle control relay.

Go to step 25.

Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

EN(H6DO)(diag)-281

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

25

Step Check CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 MΩ or 1) Connect the connector to ECM. more? 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground: (E57) No. 4 — Engine ground:

Yes Go to step 26.

26

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 27. ELECTRONIC THROTTLE CONTROL. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

27

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 28. ELECTRONIC THROTTLE CONTROL. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

28

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): (E57) No. 4 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18: (B134) No. 19 — (B134) No. 28:

29

EN(H6DO)(diag)-282

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Go to step 30.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 29.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

30

31

Step Check CHECK SENSOR OUTPUT. Is the voltage 0.81 — 0.87 V? 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. CHECK SENSOR OUTPUT. Is the voltage 1.64 — 1.70 V? Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

Yes Go to step 31.

No Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Go to step 32.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control • Poor contact of coupling connector Go to step 34.

32

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 33. ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and electronic throttle control connector. Connector & terminal (B134) No. 1 — (E57) No. 1: (B134) No. 2 — (E57) No. 2:

33

CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 (+) — Engine ground (–): (E57) No. 1 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 — Engine ground: (E57) No. 1 — Engine ground: CHECK ELECTRONIC THROTTLE CONTROL MOTOR HARNESS. Measure the resistance between electronic throttle control connectors. Connector & terminal (E57) No. 2 — (E57) No. 1:

34

35

Is the voltage 5 V or more?

Repair the short circuit to power in the harness between ECM and electronic throttle control.

Is the resistance 1 MΩ or more?

Go to step 35.

Repair the short circuit to ground in harness between ECM and electronic throttle control.

Is the resistance 1 MΩ or more?

Go to step 36.

Repair the short circuit of harness between ECM and electronic throttle control.

EN(H6DO)(diag)-283

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

36

37

38

Step CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground:

Check Yes Is the resistance less than 5 Ω? Go to step 37.

CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 2 — No. 1: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers.

Is the resistance 50 Ω or less? Go to step 38.

Does the valve return to the Repair the poor specified position? Standard contact of ECM value: 3 mm (0.12 in) from fully connector. closed position

EN(H6DO)(diag)-284

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector Replace the electronic throttle control. Replace the electronic throttle control.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DT:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

21 22

32 33

34 27

17 16

ECM

B134

B21

E37

INTAKE OIL FLOW CONTROL SOLENOID VALVE LH

1 2

1 2

E2

E38

INTAKE OIL FLOW CONTROL SOLENOID VALVE RH

B21 E37

B134

E38

1 2

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07587

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve RH. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve RH connector. Connector & terminal (B134) No. 34 — (E38) No. 1: (B134) No. 27 — (E38) No. 2: CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or FLOW CONTROL SOLENOID VALVE RH more? CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 34 — Chassis ground: (B134) No. 27 — Chassis ground: CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-286

Go to step 3.

Repair the poor contact of ECM and oil flow control solenoid valve RH connector RH.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve RH connector. Replace the oil flow control solenoid valve RH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DU:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

21 22

32 33

34 27

17 16

ECM

B134

B21

E37

INTAKE OIL FLOW CONTROL SOLENOID VALVE LH

1 2

1 2

E2

E38

INTAKE OIL FLOW CONTROL SOLENOID VALVE RH

B21 E37

B134

E38

1 2

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve RH. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 34 (+) — Chassis ground (–): (B134) No. 27 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 3. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. Measure the resistance of harness between ECM and oil flow control solenoid valve RH connector. Connector & terminal (B134) No. 34 — (E38) No. 1: (B134) No. 27 — (E38) No. 2:

CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-288

No Repair the short circuit to power supply in harness between ECM and oil flow control solenoid valve RH connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the poor Replace the oil contact of ECM flow control soleand oil flow control noid valve RH. solenoid valve RH

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DV:DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

7 17

42 43

7 15

5 14

ECM

B134

B21

E66

EXHAUST OIL FLOW CONTROL SOLENOID VALVE LH

1 2

1 2

E2

E63

EXHAUST OIL FLOW CONTROL SOLENOID VALVE RH

B21 E63

B134

E66

1 2

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve RH. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve RH connector. Connector & terminal (B134) No. 7 — (E63) No. 1: (B134) No. 15 — (E63) No. 2: CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or FLOW CONTROL SOLENOID VALVE RH more? CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 7 — Chassis ground: (B134) No. 15 — Chassis ground: CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-290

Go to step 3.

Repair the poor contact of ECM and oil flow control solenoid valve RH connector RH.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve RH connector. Replace the oil flow control solenoid valve RH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DW:DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

7 17

42 43

7 15

5 14

ECM

B134

B21

E66

EXHAUST OIL FLOW CONTROL SOLENOID VALVE LH

1 2

1 2

E2

E63

EXHAUST OIL FLOW CONTROL SOLENOID VALVE RH

B21 E63

B134

E66

1 2

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve RH. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 7 (+) — Chassis ground (–): (B134) No. 15 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 3. FLOW CONTROL SOLENOID VALVE RH CONNECTOR. Measure the resistance of harness between ECM and oil flow control solenoid valve RH connector. Connector & terminal (B134) No. 7 — (E63) No. 1: (B134) No. 15 — (E63) No. 2:

CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-292

No Repair the short circuit to power supply in harness between ECM and oil flow control solenoid valve RH connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the poor Replace the oil contact of ECM flow control soleand oil flow control noid valve RH. solenoid valve RH

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DX:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

21 22

32 33

34 27

17 16

ECM

B134

B21

E37

INTAKE OIL FLOW CONTROL SOLENOID VALVE LH

1 2

1 2

E2

E38

INTAKE OIL FLOW CONTROL SOLENOID VALVE RH

B21 E37

B134

E38

1 2

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07587

EN(H6DO)(diag)-293

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve LH. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve LH connector. Connector & terminal (B134) No. 17 — (E37) No. 1: (B134) No. 16 — (E37) No. 2: CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or FLOW CONTROL SOLENOID VALVE LH more? CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 17 — Chassis ground: (B134) No. 16 — Chassis ground: CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-294

Go to step 3.

Repair the poor contact of ECM and oil flow control solenoid valve LH connector.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve LH connector. Replace the oil flow control solenoid valve LH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DY:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

21 22

32 33

34 27

17 16

ECM

B134

B21

E37

INTAKE OIL FLOW CONTROL SOLENOID VALVE LH

1 2

1 2

E2

E38

INTAKE OIL FLOW CONTROL SOLENOID VALVE RH

B21 E37

B134

E38

1 2

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07587

EN(H6DO)(diag)-295

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve LH. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 17 (+) — Chassis ground (–): (B134) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 3. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. Measure the resistance of harness between ECM and oil flow control solenoid valve LH connector. Connector & terminal (B134) No. 17 — (E37) No. 1: (B134) No. 16 — (E37) No. 2:

CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-296

No Repair the short circuit to power supply in harness between ECM and oil flow control solenoid valve LH connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the poor Replace the oil contact of ECM flow control soleand oil flow control noid valve LH. solenoid valve LH

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

DZ:DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

7 17

42 43

7 15

5 14

ECM

B134

B21

E66

EXHAUST OIL FLOW CONTROL SOLENOID VALVE LH

1 2

1 2

E2

E63

EXHAUST OIL FLOW CONTROL SOLENOID VALVE RH

B21 E63

B134

E66

1 2

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07589

EN(H6DO)(diag)-297

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 2. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve LH. 3) Measure the resistance of harness between ECM and oil flow control solenoid valve LH connector. Connector & terminal (B134) No. 5 — (E66) No. 1: (B134) No. 14 — (E66) No. 2: CHECK HARNESS BETWEEN ECM AND OIL Is the resistance 1 MΩ or FLOW CONTROL SOLENOID VALVE LH more? CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 5 — Chassis ground: (B134) No. 14 — Chassis ground: CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-298

Go to step 3.

Repair the poor contact of ECM and oil flow control solenoid valve LH connector.

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the short circuit to ground in harness between ECM and oil flow control solenoid valve LH connector. Replace the oil flow control solenoid valve LH.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EA:DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2) DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: Improper idling CAUTION: After repair or replacement of faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

7 17

42 43

7 15

5 14

ECM

B134

B21

E66

EXHAUST OIL FLOW CONTROL SOLENOID VALVE LH

1 2

1 2

E2

E63

EXHAUST OIL FLOW CONTROL SOLENOID VALVE RH

B21 E63

B134

E66

1 2

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07589

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step Check Yes CHECK HARNESS BETWEEN ECM AND OIL Is the voltage less than 1 V? Go to step 2. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and oil flow control solenoid valve LH. 3) Measure the voltage between ECM and chassis ground. Connector & terminal (B134) No. 5 (+) — Chassis ground (–): (B134) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 Ω? Go to step 3. FLOW CONTROL SOLENOID VALVE LH CONNECTOR. Measure the resistance of harness between ECM and oil flow control solenoid valve LH connector. Connector & terminal (B134) No. 5 — (E66) No. 1: (B134) No. 14 — (E66) No. 2:

CHECK OIL FLOW CONTROL SOLENOID Is the resistance 6 — 12 Ω? VALVE. Measure the resistance between oil flow control solenoid valve terminals. Terminals No. 1 — No. 2:

EN(H6DO)(diag)-300

No Repair the short circuit to power supply in harness between ECM and oil flow control solenoid valve LH connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and oil flow control solenoid valve RH connector • Poor contact of coupling connector Repair the poor Replace the oil contact of ECM flow control soleand oil flow control noid valve LH. solenoid valve LH

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EB:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-301

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BATTERY

1

4

E25

3

2

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

3

B220

4

REAR OXYGEN SENSOR LH

1

A/F, OXYGEN SENSOR RELAY

E61

9

10

11

12

16

15

13

14

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

2 4

B22

B503

1 2 3 4 5 6 7 8

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. Has water entered the connec- Completely Go to step 3. tor? remove any water inside.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 19 — (E47) No. 3: (B136) No. 18 — (E47) No. 4:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 19 — Chassis ground: (B136) No. 18 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E47) No. 3 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E47) No. 4 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E47) No. 3 (+) — Chassis ground (–): (E47) No. 4 (+) — Chassis ground (–):

Is the resistance 1 MΩ or more?

Go to step 5.

Is the voltage 4.5 V or more?

Go to step 7.

Go to step 6.

Is the voltage 4.95 V or more? Go to step 7.

Go to step 8.

Is the voltage 8 V or more?

Repair the poor contact of ECM connector.

8

CHECK EXHAUST SYSTEM.

9

CHECK AIR INTAKE SYSTEM.

Are there holes or loose bolts on exhaust system? Are there holes, loose bolts or disconnection of hose on air intake system?

5

6

7

EN(H6DO)(diag)-303

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Repair the exhaust system. Repair the air intake system.

Go to step 9. Go to step 10.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10

11

12

Step CHECK FUEL PRESSURE. WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the measured value 333 — 343 kPa (3.4 — 3.5 kgf/cm2, 48.4 — 49.8 psi)?

Yes Go to step 11.

No Repair the following item. Fuel pressure is too high: • Clogged fuel line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel line

Is the temperature 75°C (167°F) or more?

Go to step 12.

Replace the engine coolant temperature sensor.

Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)?

Go to step 13.

Replace the mass air flow and intake air temperature sensor.

EN(H6DO)(diag)-304

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

13

14

15

16

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Subtract ambient temperature Go to step 14. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

No Check the mass air flow and intake air temperature sensor.

Is the voltage 490 mV or more? Go to step 15.

Go to step 16.

Is the voltage 250 mV or less? Go to step 17.

Go to step 16.

Has water entered the connec- Completely tor? remove any water inside.

Go to step 18.

EN(H6DO)(diag)-305

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

17

18

19

Step CHECK FRONT OXYGEN (A/F) SENSOR USING REAR OXYGEN SENSOR SIGNAL. 1) Warm up the engine until engine coolant temperature is higher than 75°C (167°F), then keep the engine idling for 5 minutes or more. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E61) No. 3: (B135) No. 30 — (E61) No. 4:

Check Is a voltage of 250 mV or less maintained for 5 minutes or more?

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E61) No. 3 (+) — Chassis ground (–):

Is the voltage 0.2 — 0.5 V?

Yes No Replace the front Go to step 18. oxygen (A/F) sensor.

Is the resistance less than 1 Ω? Go to step 19.

EN(H6DO)(diag)-306

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EC:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1) DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-307

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BATTERY

1

4

E25

3

2

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

3

B220

4

REAR OXYGEN SENSOR LH

1

A/F, OXYGEN SENSOR RELAY

E61

9

10

11

12

16

15

13

14

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

2 4

B22

B503

1 2 3 4 5 6 7 8

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. Has water entered the connec- Completely Go to step 3. tor? remove any water inside.

EN(H6DO)(diag)-308

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 19 — (E47) No. 3: (B136) No. 18 — (E47) No. 4:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B136) No. 19 — Chassis ground: (B136) No. 18 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E47) No. 3 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E47) No. 4 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E47) No. 3 (+) — Chassis ground (–): (E47) No. 4 (+) — Chassis ground (–):

Is the resistance 1 MΩ or more?

Go to step 5.

Is the voltage 4.5 V or more?

Go to step 7.

Go to step 6.

Is the voltage 4.95 V or more? Go to step 7.

Go to step 8.

Is the voltage 8 V or more?

Repair the poor contact of ECM connector.

8

CHECK EXHAUST SYSTEM.

9

CHECK AIR INTAKE SYSTEM.

Are there holes or loose bolts on exhaust system? Are there holes, loose bolts or disconnection of hose on air intake system?

5

6

7

EN(H6DO)(diag)-309

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Repair the exhaust system. Repair the air intake system.

Go to step 9. Go to step 10.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10

11

12

Step CHECK FUEL PRESSURE. WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the measured value 333 — 343 kPa (3.4 — 3.5 kgf/cm2, 48.4 — 49.8 psi)?

Yes Go to step 11.

No Repair the following item. Fuel pressure is too high: • Clogged fuel line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel line

Is the temperature 75°C (167°F) or more?

Go to step 12.

Replace the engine coolant temperature sensor.

Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)?

Go to step 13.

Replace the mass air flow and intake air temperature sensor.

EN(H6DO)(diag)-310

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

13

14

15

16

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Subtract ambient temperature Go to step 14. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

No Check the mass air flow and intake air temperature sensor.

Is the voltage 490 mV or more? Go to step 15.

Go to step 16.

Is the voltage 250 mV or less? Go to step 17.

Go to step 16.

Has water entered the connec- Completely tor? remove any water inside.

Go to step 18.

EN(H6DO)(diag)-311

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

17

18

19

Step CHECK FRONT OXYGEN (A/F) SENSOR USING REAR OXYGEN SENSOR SIGNAL. 1) Warm up the engine until engine coolant temperature is higher than 75°C (167°F), then keep the engine idling for 5 minutes or more. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 20 — (E61) No. 3: (B135) No. 30 — (E61) No. 4:

Check Is a voltage of 0.8 V or more maintained for 5 minutes or more?

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E61) No. 3 (+) — Chassis ground (–):

Is the voltage 0.2 — 0.5 V?

Yes No Replace the front Go to step 18. oxygen (A/F) sensor.

Is the resistance less than 1 Ω? Go to step 19.

EN(H6DO)(diag)-312

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

ED:DTC P2098 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 2 DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-313

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BATTERY

1

4

E25

3

2

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

3

B220

4

REAR OXYGEN SENSOR LH

1

A/F, OXYGEN SENSOR RELAY

E61

9

10

11

12

16

15

13

14

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

2 4

B22

B503

1 2 3 4 5 6 7 8

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. Has water entered the connec- Completely Go to step 3. tor? remove any water inside.

EN(H6DO)(diag)-314

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 8 — (E24) No. 3: (B135) No. 20 — (E24) No. 4:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 8 — Chassis ground: (B135) No. 20 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E24) No. 3 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 4 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 3 (+) — Chassis ground (–): (E24) No. 4 (+) — Chassis ground (–):

Is the resistance 1 MΩ or more?

Go to step 5.

Is the voltage 4.5 V or more?

Go to step 7.

Go to step 6.

Is the voltage 4.95 V or more? Go to step 7.

Go to step 8.

Is the voltage 8 V or more?

Repair the poor contact of ECM connector.

8

CHECK EXHAUST SYSTEM.

9

CHECK AIR INTAKE SYSTEM.

Are there holes or loose bolts on exhaust system? Are there holes, loose bolts or disconnection of hose on air intake system?

5

6

7

EN(H6DO)(diag)-315

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Repair the exhaust system. Repair the air intake system.

Go to step 9. Go to step 10.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10

11

12

Step CHECK FUEL PRESSURE. WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the measured value 333 — 343 kPa (3.4 — 3.5 kgf/cm2, 48.4 — 49.8 psi)?

Yes Go to step 11.

No Repair the following item. Fuel pressure is too high: • Clogged fuel line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel line

Is the temperature 75°C (167°F) or more?

Go to step 12.

Replace the engine coolant temperature sensor.

Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)?

Go to step 13.

Replace the mass air flow and intake air temperature sensor.

EN(H6DO)(diag)-316

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

13

14

15

16

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Subtract ambient temperature Go to step 14. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

No Check the mass air flow and intake air temperature sensor.

Is the voltage 490 mV or more? Go to step 15.

Go to step 16.

Is the voltage 250 mV or less? Go to step 17.

Go to step 16.

Has water entered the connec- Completely tor? remove any water inside.

Go to step 18.

EN(H6DO)(diag)-317

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

17

18

19

Step CHECK FRONT OXYGEN (A/F) SENSOR USING REAR OXYGEN SENSOR SIGNAL. 1) Warm up the engine until engine coolant temperature is higher than 75°C (167°F), then keep the engine idling for 5 minutes or more. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 28 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

Check Is a voltage of 250 mV or less maintained for 5 minutes or more?

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Is the voltage 0.2 — 0.5 V?

Yes No Replace the front Go to step 18. oxygen (A/F) sensor.

Is the resistance less than 1 Ω? Go to step 19.

EN(H6DO)(diag)-318

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EE:DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2 DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: BATTERY

1

4

E24

3

FRONT OXYGEN (A/F) SENSOR RH

2

2

9 10

4

M/B No. 15 12 11

3

FRONT OXYGEN (A/F) SENSOR LH

B220

1

A/F, OXYGEN SENSOR RELAY

E47

4

2

1

3

6

5

7

8

E3 B22

B503

B : B135

D : B137

C6

C5

C18

C19

C : B136

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

C9

B20

B8

B2

B1

* * *

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E24

E47

1 2 3 4 5 6 7 8

1 2 3 4

B22

B503

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-319

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07769

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

BATTERY

1

4

E25

3

2

9 10

2

M/B No. 15 12 11

REAR OXYGEN SENSOR RH

3

B220

4

REAR OXYGEN SENSOR LH

1

A/F, OXYGEN SENSOR RELAY

E61

9

10

11

12

16

15

13

14

E3 B22

* * *

B83

B : B135

C : B136

D : B137

C9

J/C

ECM

A3 D5 D3 D1 A4 A6

A : B134

B6

B28

B5

B30

C20

* * *

J/C

B503

35 37 34 40 36

B21 E2

*

: TERMINAL No. OPTIONAL ARRANGEMENT

E

E

E25

1 3

E61

B83

2 4

B22

B503

1 2 3 4 5 6 7 8

A : B134

B21 1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

B220

1 3 4 2

1

2

5 7 8 6

9 11 12 10

B : B135

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

13 15 16 14

17 18 20 21 19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

CHECK FRONT OXYGEN (A/F) SENSOR CONNECTOR AND COUPLING CONNECTOR.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07770

Yes No Check DTC using Go to step 2. “List of Diagnostic Trouble Code (DTC)”. Has water entered the connec- Completely Go to step 3. tor? remove any water inside.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and front oxygen (A/F) sensor. 3) Measure the resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B135) No. 8 — (E24) No. 3: (B135) No. 20 — (E24) No. 4:

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and front oxygen (A/F) sensor connector • Poor contact of coupling connector Repair the ground short circuit of harness between ECM and front oxygen (A/F) sensor connector.

CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 8 — Chassis ground: (B135) No. 20 — Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between front oxygen (A/F) sensor connector and chassis ground. Connector & terminal (E24) No. 3 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 4 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL FOR ECM. Measure the voltage between front oxygen (A/ F) sensor connector and chassis ground. Connector & terminal (E24) No. 3 (+) — Chassis ground (–): (E24) No. 4 (+) — Chassis ground (–):

Is the resistance 1 MΩ or more?

Go to step 5.

Is the voltage 4.5 V or more?

Go to step 7.

Go to step 6.

Is the voltage 4.95 V or more? Go to step 7.

Go to step 8.

Is the voltage 8 V or more?

Repair the poor contact of ECM connector.

8

CHECK EXHAUST SYSTEM.

9

CHECK AIR INTAKE SYSTEM.

Are there holes or loose bolts on exhaust system? Are there holes, loose bolts or disconnection of hose on air intake system?

5

6

7

EN(H6DO)(diag)-321

Repair the short circuit of harness to power supply between ECM and front oxygen (A/F) sensor connector. After repair, replace the ECM.

Repair the exhaust system. Repair the air intake system.

Go to step 9. Go to step 10.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

10

11

12

Step CHECK FUEL PRESSURE. WARNING: Place “NO OPEN FLAMES” signs near the working area. CAUTION: Be careful not to spill fuel. 1) Connect the front oxygen (A/F) sensor connector. 2) Measure the fuel pressure. CAUTION: Release fuel pressure before removing the fuel pressure gauge. CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm up completely. 2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual.

Check Is the measured value 333 — 343 kPa (3.4 — 3.5 kgf/cm2, 48.4 — 49.8 psi)?

Yes Go to step 11.

No Repair the following item. Fuel pressure is too high: • Clogged fuel line or bent hose Fuel pressure is too low: • Improper fuel pump discharge • Clogged fuel line

Is the temperature 75°C (167°F) or more?

Go to step 12.

Replace the engine coolant temperature sensor.

Is the measured value 2.0 — 5.0 g/s (0.26 — 0.66 lb/m)?

Go to step 13.

Replace the mass air flow and intake air temperature sensor.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

13

14

15

16

Step CHECK MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm up engine until coolant temperature is higher than 75°C (167°F). 2) Place the select lever in “P” range or “N” range. 3) Turn the A/C switch to OFF. 4) Turn all the accessory switches to OFF. 5) Open the front hood. 6) Measure the ambient temperature. 7) Read the data of mass air flow and intake air temperature sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and keep the engine speed at 3,000 rpm. (2 minutes maximum) 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR DATA. 1) Warm up the engine until engine coolant temperature is above 75°C (167°F), and rapidly reduce the engine speed from 3,000 rpm. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR.

Check Yes Subtract ambient temperature Go to step 14. from intake air temperature. Is the obtained value –10 — 50°C (–18 — 90°F)?

No Check the mass air flow and intake air temperature sensor.

Is the voltage 490 mV or more? Go to step 15.

Go to step 16.

Is the voltage 250 mV or less? Go to step 17.

Go to step 16.

Has water entered the connec- Completely tor? remove any water inside.

Go to step 18.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

17

18

19

Step CHECK FRONT OXYGEN (A/F) SENSOR USING REAR OXYGEN SENSOR SIGNAL. 1) Warm up the engine until engine coolant temperature is higher than 75°C (167°F), then keep the engine idling for 5 minutes or more. 2) Read the data of rear oxygen sensor signal using Subaru Select Monitor or general scan tool. NOTE: • Subaru Select Monitor For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. • General scan tool For detailed operation procedures, refer to the general scan tool operation manual. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM and rear oxygen sensor. 3) Measure the resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 28 — (E25) No. 3: (B135) No. 30 — (E25) No. 4:

Check Is a voltage of 0.8 V or more maintained for 5 minutes or more?

CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between rear oxygen sensor connector and chassis ground. Connector & terminal (E25) No. 3 (+) — Chassis ground (–):

Is the voltage 0.2 — 0.5 V?

Yes No Replace the front Go to step 18. oxygen (A/F) sensor.

Is the resistance less than 1 Ω? Go to step 19.

EN(H6DO)(diag)-324

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of coupling connector Replace the rear Repair the harness oxygen sensor. and connector.

• Open circuit in harness between ECM and rear oxygen sensor connector • Poor contact of ECM connector • Poor contact of coupling connector

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EF:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: ELECTRONIC THROTTLE CONTROL RELAY BATTERY

B220 M/B No. 13 16 15 M/B No. 16 13 14

B7

B17

MAIN RELAY

ECM

C4

D : B137 A28 A18

C : B136 A19 A1 A2 A29

B : B135

A3 D5 D3 D1 A4 A6

A : B134

B138

* *

24 25

28 39 38 6

35 37 34 40 36

B21

E

J/C

ELECTRONIC THROTTLE CONTROL

E

1 2 3 4 5 6 7 8

1 2 3 4 5 6

B220

1 3 4 2

5 7 8 6

A : B134

B138

E57

9 11 12 10

4 6

5 1 2 3

E2

1 2 8 9 10 18 19 20 28 29 30

17 18 20 21 19

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

*

E

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

C : B136

13 15 16 14

E57

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07772

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

6

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 13 and No. 14 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 15 — No. 16: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connector from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 — Chassis ground: (B220) No. 15 — Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B135) No. 7 — (B220) No. 15: (B135) No. 17 — (B220) No. 14: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: (B134) No. 28 — Chassis ground:

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Go to step 3.

Repair the open or ground short circuit of power supply circuit.

Is the voltage 10 V or more?

Repair the short Go to step 4. circuit to power in harness between ECM and electronic throttle control relay.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the ground short circuit of harness between ECM and electronic throttle control relay.

Is the resistance less than 1 Ω? Go to step 6.

Repair the open circuit of harness between ECM and electronic throttle control relay.

Go to step 7.

Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

7

Step Check CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance 1 MΩ or 1) Connect the connector to ECM. more? 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground: (E57) No. 4 — Engine ground:

Yes Go to step 8.

8

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 9. ELECTRONIC THROTTLE CONTROL. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

9

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 10. ELECTRONIC THROTTLE CONTROL. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

10

CHECK HARNESS BETWEEN ECM AND Is the voltage 5 V or more? ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): (E57) No. 4 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18: (B134) No. 19 — (B134) No. 28:

11

EN(H6DO)(diag)-327

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

Go to step 12.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 11.

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

12

13

Step Check CHECK SENSOR OUTPUT. Is the voltage 0.81 — 0.87 V? 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of main throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”. CHECK SENSOR OUTPUT. Is the voltage 1.64 — 1.70 V? Read the data of sub throttle sensor signal using Subaru Select Monitor. NOTE: For detailed operation procedures, refer to “READ CURRENT DATA FOR ENGINE”.

Yes Go to step 13.

No Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Go to step 14.

Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control • Poor contact of coupling connector Go to step 16.

14

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 15. ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and electronic throttle control connector. Connector & terminal (B134) No. 1 — (E57) No. 1: (B134) No. 2 — (E57) No. 2:

15

CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Connect the connector to ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 (+) — Engine ground (–): (E57) No. 1 (+) — Engine ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL MOTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 2 — Engine ground: (E57) No. 1 — Engine ground: CHECK ELECTRONIC THROTTLE CONTROL MOTOR HARNESS. Measure the resistance between electronic throttle control connectors. Connector & terminal (E57) No. 2 — (E57) No. 1:

16

17

Is the voltage 5 V or more?

Repair the short circuit to power in the harness between ECM and electronic throttle control.

Is the resistance 1 MΩ or more?

Go to step 17.

Repair the short circuit to ground in harness between ECM and electronic throttle control.

Is the resistance 1 MΩ or more?

Go to step 18.

Repair the short circuit of harness between ECM and electronic throttle control.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

18

19

20

Step CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT. Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 3 — Chassis ground: (B134) No. 4 — Chassis ground: (B134) No. 6 — Chassis ground: (B137) No. 1 — Chassis ground: (B137) No. 3 — Chassis ground: (B137) No. 5 — Chassis ground:

Check Yes Is the resistance less than 5 Ω? Go to step 19.

CHECK ELECTRONIC THROTTLE CONTROL. Measure the resistance between electronic throttle control terminals. Terminals No. 2 — No. 1: CHECK ELECTRONIC THROTTLE CONTROL. Move the throttle valve to the fully open and fully closed positions with fingers. Check that the valve returns to the specified position when releasing fingers.

Is the resistance 50 Ω or less? Go to step 20.

Does the valve return to the Repair the poor specified position? Standard contact of ECM value: 3 mm (0.12 in) from fully connector. closed position

EN(H6DO)(diag)-329

No Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of coupling connector Replace the electronic throttle control. Replace the electronic throttle control.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EG:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance • Engine stalls. CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: ELECTRONIC THROTTLE CONTROL RELAY BATTERY

B220 M/B No. 13 16 15 M/B No. 16 13 14

B7

B17

MAIN RELAY

ECM

C4

D : B137 A28 A18

C : B136 A19 A1 A2 A29

B : B135

A3 D5 D3 D1 A4 A6

A : B134

B138

* *

24 25

28 39 38 6

35 37 34 40 36

B21

E

J/C

ELECTRONIC THROTTLE CONTROL

E

1 2 3 4 5 6 7 8

1 2 3 4 5 6

B220

1 3 4 2

5 7 8 6

A : B134

B138

E57

9 11 12 10

4 6

5 1 2 3

E2

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

13 15 16 14

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

*

E

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

C : B136 17 18 20 21 19

E57

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07772

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

5

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Connect the battery to terminals No. 13 and No. 14 of electronic throttle control relay. 4) Measure the resistance between electronic throttle control relay terminals. Terminals No. 15 — No. 16: CHECK POWER SUPPLY OF ELECTRONIC THROTTLE CONTROL RELAY. Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 16 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Disconnect the connector from ECM. 2) Turn the ignition switch to ON. 3) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Measure the resistance between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 14 — Chassis ground: (B220) No. 15 — Chassis ground: CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. Measure the resistance between ECM and electronic throttle control relay connector. Connector & terminal (B135) No. 7 — (B220) No. 15: (B135) No. 17 — (B220) No. 14:

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Go to step 3.

Repair the open or ground short circuit of power supply circuit.

Is the voltage 10 V or more?

Repair the short Go to step 4. circuit to power in harness between ECM and electronic throttle control relay.

Is the resistance 1 MΩ or more?

Go to step 5.

Is the resistance less than 1 Ω? Repair the poor contact of ECM connector.

EN(H6DO)(diag)-331

Repair the ground short circuit of harness between ECM and electronic throttle control relay.

Repair the open circuit of harness between ECM and electronic throttle control relay.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EH:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: ELECTRONIC THROTTLE CONTROL RELAY BATTERY

B220 M/B No. 13 16 15 M/B No. 16 13 14

B7

B17

MAIN RELAY

ECM

C4

D : B137 A28 A18

C : B136 A19 A1 A2 A29

B : B135

A3 D5 D3 D1 A4 A6

A : B134

B138

* *

24 25

28 39 38 6

35 37 34 40 36

B21

E

J/C

ELECTRONIC THROTTLE CONTROL

E

1 2 3 4 5 6 7 8

1 2 3 4 5 6

B220

1 3 4 2

5 7 8 6

A : B134

B138

E57

9 11 12 10

4 6

5 1 2 3

E2

1 2 8 9 10 18 19 20 28 29 30

17 18 20 21 19

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

*

E

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

C : B136

13 15 16 14

E57

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07772

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Remove the electronic throttle control relay. 3) Measure the resistance between electronic throttle control relay terminals. Terminals No. 15 — No. 16: CHECK SHORT CIRCUIT OF ELECTRONIC THROTTLE CONTROL RELAY POWER SUPPLY. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control relay connector and chassis ground. Connector & terminal (B220) No. 15 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 17 — Chassis ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Replace the electronic throttle control relay.

Is the voltage 10 V or more?

Repair the short Go to step 3. circuit to power in harness between ECM and electronic throttle control relay.

Is the resistance 1 MΩ or more?

Repair the poor contact of ECM connector.

Repair the ground short circuit of harness between ECM and electronic throttle control relay.

EI: DTC P2109 THROTTLE/PEDAL POSITION SENSOR “A” MINIMUM STOP PERFORMANCE NOTE: For the diagnostic procedure, refer to DTC P2101.

EN(H6DO)(diag)-333

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EJ:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5 6

ACCELERATOR PEDAL POSITION SENSOR

B83

B138

* *

* *

J/C

B22 B30 B31 B21 B29 B23 C4

J/C

B315

A : B134 B : B135 ECM C : B136

A3 D5 D3 D1 A4 A6

D : B137

35 37 34 40 36

B21 E2

A : B134 B315 1 2 3 4 5 6

B83

B138

1 2 3 4 5 6 7 8

1 2 8 9 10 18 19 20 28 29 30

B : B135

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

: TERMINAL No. OPTIONAL ARRANGEMENT

*

E

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-334

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07591

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 21 — Chassis ground: (B135) No. 23 — Chassis ground: (B135) No. 23 — (B136) No. 4: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 — Chassis ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector.

Is the resistance 1 MΩ or more?

Replace the accelerator pedal.

Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective.

EN(H6DO)(diag)-335

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EK:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5 6

ACCELERATOR PEDAL POSITION SENSOR

B83

B138

* *

* *

J/C

B22 B30 B31 B21 B29 B23 C4

J/C

B315

A : B134 B : B135 ECM C : B136

A3 D5 D3 D1 A4 A6

D : B137

35 37 34 40 36

B21 E2

A : B134 B315 1 2 3 4 5 6

B83

B138

1 2 3 4 5 6 7 8

1 2 8 9 10 18 19 20 28 29 30

B : B135

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

: TERMINAL No. OPTIONAL ARRANGEMENT

*

E

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-336

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07591

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 Ω? Go to step 2. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance of harness between ECM and accelerator pedal position sensor connector. Connector & terminal (B135) No. 23 — (B315) No. 6: (B135) No. 29 — (B315) No. 5: CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Ω? Go to step 3. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 5 — Chassis ground:

CHECK HARNESS BETWEEN ECM AND AC- Is the voltage 5 V or more? CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 MΩ or CELERATOR PEDAL POSITION SENSOR more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B135) No. 21 — (B135) No. 23:

EN(H6DO)(diag)-337

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

Repair the poor contact of accelerator pedal position sensor connector. Replace the accelerator pedal if defective.

No Repair the open circuit of harness between ECM and accelerator pedal position sensor connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EL:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5 6

ACCELERATOR PEDAL POSITION SENSOR

B83

B138

* *

* *

J/C

B22 B30 B31 B21 B29 B23 C4

J/C

B315

A : B134 B : B135 ECM C : B136

A3 D5 D3 D1 A4 A6

D : B137

35 37 34 40 36

B21 E2

A : B134 B315 1 2 3 4 5 6

B83

B138

1 2 3 4 5 6 7 8

1 2 8 9 10 18 19 20 28 29 30

B : B135

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

: TERMINAL No. OPTIONAL ARRANGEMENT

*

E

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-338

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B135) No. 22 — Chassis ground: (B135) No. 31 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 3 — Chassis ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector.

Is the resistance 1 MΩ or more?

Replace the accelerator pedal.

Repair the short circuit to ground in harness between ECM and accelerator pedal position sensor connector. Replace the ECM if defective.

EN(H6DO)(diag)-339

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EM:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM:

1 2 3 4 5 6

ACCELERATOR PEDAL POSITION SENSOR

B83

B138

* *

* *

J/C

B22 B30 B31 B21 B29 B23 C4

J/C

B315

A : B134 B : B135 ECM C : B136

A3 D5 D3 D1 A4 A6

D : B137

35 37 34 40 36

B21 E2

A : B134 B315 1 2 3 4 5 6

B83

B138

1 2 3 4 5 6 7 8

1 2 8 9 10 18 19 20 28 29 30

B : B135

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

: TERMINAL No. OPTIONAL ARRANGEMENT

*

E

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-340

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

4

Step Check Yes CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 Ω? Go to step 2. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from ECM and accelerator pedal position sensor. 3) Measure the resistance of harness between ECM and accelerator pedal position sensor connector. Connector & terminal (B135) No. 31 — (B315) No. 3: (B135) No. 30 — (B315) No. 2: CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Ω? Go to step 3. CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Connect the connector to ECM. 2) Measure the resistance between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 2 — Chassis ground:

CHECK HARNESS BETWEEN ECM AND AC- Is the voltage 5 V or more? CELERATOR PEDAL POSITION SENSOR CONNECTOR. 1) Turn the ignition switch to ON. 2) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 3 (+) — Chassis ground (–): CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 MΩ or CELERATOR PEDAL POSITION SENSOR more? CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B135) No. 22 — (B135) No. 31:

EN(H6DO)(diag)-341

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

Repair the poor contact of accelerator pedal position sensor connector. Replace the accelerator pedal if defective.

No Repair the open circuit of harness between ECM and accelerator pedal position sensor connector.

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 4.

Repair the short circuit to power supply in the harness between the ECM and accelerator pedal position sensor connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EN:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION TROUBLE SYMPTOM: • Improper idling • Poor driving performance CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . WIRING DIAGRAM: ELECTRONIC THROTTLE CONTROL RELAY BATTERY

B220 M/B No. 13 16 15 M/B No. 16 13 14

B7

B17

MAIN RELAY

ECM

C4

D : B137 A28 A18

C : B136 A19 A1 A2 A29

B : B135

A3 D5 D3 D1 A4 A6

A : B134

B138

* *

24 25

28 39 38 6

35 37 34 40 36

B21

E

J/C

ELECTRONIC THROTTLE CONTROL

E

1 2 3 4 5 6 7 8

1 2 3 4 5 6

B220

1 3 4 2

5 7 8 6

A : B134

B138

E57

9 11 12 10

4 6

5 1 2 3

E2

1 2 8 9 10 18 19 20 28 29 30

17 18 20 21 19

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

*

E

: TERMINAL No. OPTIONAL ARRANGEMENT

B : B135

C : B136

13 15 16 14

E57

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 28 29 26 27 30 31

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

EN-07772

EN(H6DO)(diag)-342

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

Step CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from the ECM and electronic throttle control. 3) Measure the resistance between ECM and chassis ground. Connector & terminal (B134) No. 19 — Chassis ground: (B134) No. 18 — Chassis ground: (B134) No. 18 — (B136) No. 4: (B134) No. 28 — Chassis ground: CHECK SHORT CIRCUIT INSIDE THE ECM. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 — Engine ground: (E57) No. 4 — Engine ground:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the ground short circuit of harness between ECM and electronic throttle control connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the ground short circuit of harness between ECM and electronic throttle control connector. Replace the ECM if defective. Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit in harness between ECM and electronic throttle control connector • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector Go to step 6.

3

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Ω? Go to step 4. ELECTRONIC THROTTLE CONTROL. 1) Disconnect the connector from ECM. 2) Measure the resistance of harness between ECM and electronic throttle control connector. Connector & terminal (B134) No. 18 — (E57) No. 6: (B134) No. 28 — (E57) No. 4: (B134) No. 29 — (E57) No. 3:

4

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 Ω? Go to step 5. ELECTRONIC THROTTLE CONTROL. 1) Connect the connector to ECM. 2) Measure the resistance between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 3 — Engine ground:

5

CHECK HARNESS BETWEEN ECM AND ELECTRONIC THROTTLE CONTROL. 1) Turn the ignition switch to ON. 2) Measure the voltage between electronic throttle control connector and engine ground. Connector & terminal (E57) No. 6 (+) — Engine ground (–): (E57) No. 4 (+) — Engine ground (–):

Is the voltage 5 V or more?

EN(H6DO)(diag)-343

Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

6

Step Check CHECK HARNESS BETWEEN ECM AND Is the resistance 1 MΩ or ELECTRONIC THROTTLE CONTROL. more? 1) Turn the ignition switch to OFF. 2) Disconnect the connector from ECM. 3) Measure the resistance between ECM connectors. Connector & terminal (B134) No. 19 — (B134) No. 18: (B134) No. 19 — (B134) No. 28:

EN(H6DO)(diag)-344

Yes Repair the poor contact of electronic throttle control connector. Replace the electronic throttle control if defective.

No Repair the short circuit of harness to power supply between ECM and electronic throttle control connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EO:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . TROUBLE SYMPTOM: • Improper idling • Poor driving performance WIRING DIAGRAM:

1 2 3 4 5 6

ACCELERATOR PEDAL POSITION SENSOR

B83

B138

* *

* *

J/C

B22 B30 B31 B21 B29 B23 C4

J/C

B315

A : B134 B : B135 ECM C : B136

A3 D5 D3 D1 A4 A6

D : B137

35 37 34 40 36

B21 E2

A : B134 B315 1 2 3 4 5 6

B83

B138

1 2 3 4 5 6 7 8

1 2 8 9 10 18 19 20 28 29 30

B : B135

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34 C : B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 31 32 28 29 30

: TERMINAL No. OPTIONAL ARRANGEMENT

*

E

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

D : B137 5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 24 25 18 19 20 21 22 23 26 27 28 29 30 31

EN(H6DO)(diag)-345

B21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

35 43 48

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

1

2

3

Step CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Turn the ignition switch to ON. 2) Measure the voltage between ECM and chassis ground. Connector & terminal Main accelerator pedal position sensor signal (B135) No. 23 (+) — Chassis ground (–): Sub accelerator pedal position sensor signal (B135) No. 31 (+) — Chassis ground (–): CHECK ACCELERATOR PEDAL POSITION SENSOR OUTPUT. 1) Measure the voltage between accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 6 (+) — Chassis ground (–): (B315) No. 3 (+) — Chassis ground (–):

Check Yes Is the difference between the Go to step 3. measured value of main accelerator pedal position sensor signal and the measured value of sub accelerator pedal position sensor signal 0 V?

No Go to step 2.

Is the difference between the measured value of main accelerator pedal position sensor signal and the measured value of sub accelerator pedal position sensor signal 0 V?

Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and accelerator pedal position sensor connector. • Ground short circuit of harness between ECM and accelerator pedal position sensor connector. • Poor contact of coupling connector Repair the harness and connector. NOTE: In this case, repair the following item: • Open circuit of harness between ECM and accelerator pedal position sensor connector. • Open circuit of harness between ECM and engine ground • Poor contact of ECM connector • Poor contact of coupling connector

Replace the accelerator pedal.

CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 5 Ω? Repair the poor CELERATOR PEDAL POSITION SENSOR contact of ECM CONNECTOR. connector. Measure the resistance of harness between the accelerator pedal position sensor connector and chassis ground. Connector & terminal (B315) No. 5 — Chassis ground: (B315) No. 2 — Chassis ground:

EN(H6DO)(diag)-346

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

EP:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE DTC DETECTING CONDITION: • Detected when two consecutive driving cycles with fault occur. • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check DTC using “List of Diagnostic Trouble Code (DTC)”.

No Replace the ECM.

NOTE: The barometric pressure sensor is built into the ECM.

EQ:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

EN(H6DO)(diag)-347

Yes Check DTC using “List of Diagnostic Trouble Code (DTC)”.

No Replace the ECM.

NOTE: The barometric pressure sensor is built into the ECM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) ENGINE (DIAGNOSTICS)

ER:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH DTC DETECTING CONDITION: • Immediately at fault recognition • GENERAL DESCRIPTION CAUTION: After servicing or replacing faulty parts, perform Clear Memory Mode , and Inspection Mode . 1

Step Check CHECK FOR ANY OTHER DTC ON DISPLAY. Is any other DTC displayed?

Yes Check DTC using “List of Diagnostic Trouble Code (DTC)”.

No Replace the ECM.

NOTE: The barometric pressure sensor is built into the ECM.

ES:DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION NOTE: For the diagnostic procedure, refer to LAN section.

ET:DTC U0101 CAN (TCU) DATA NOT LOADED NOTE: For the diagnostic procedure, refer to LAN section.

EU:DTC U0122 CAN (VDC) DATA NOT LOADED NOTE: For the diagnostic procedure, refer to LAN section.

EV:DTC U0140 CAN (BCU) DATA NOT LOADED NOTE: For the diagnostic procedure, refer to LAN section.

EW:DTC U0402 CAN (TCU) DATA ABNORMAL NOTE: For the diagnostic procedure, refer to LAN section.

EX:DTC U0416 CAN (VDC) DATA ABNORMAL NOTE: For the diagnostic procedure, refer to LAN section.

EY:DTC U0422 CAN (BCU) DATA ABNORMAL NOTE: For the diagnostic procedure, refer to LAN section.

EN(H6DO)(diag)-348

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General Diagnostic Table ENGINE (DIAGNOSTICS)

19.General Diagnostic Table A: INSPECTION NOTE: Malfunction of parts other than those listed is also possible. Symptoms

1. Engine stalls during idling.

2. Rough idling

3. Engine does not return to idle.

4. Poor acceleration

Problem parts 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Ignition parts (*1) 4) Engine coolant temperature sensor (*2) 5) Crankshaft position sensor (*3) 6) Camshaft position sensor (*3) 7) Fuel injection parts (*4) 8) Electronic throttle control 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Ignition parts (*1) 5) Air intake system (*5) 6) Fuel injection parts (*4) 7) Electronic throttle control 8) Crankshaft position sensor (*3) 9) Camshaft position sensor (*3) 10) Oxygen sensor 11) Fuel pump and fuel pump relay 12) EGR valve 1) Engine coolant temperature sensor 2) Electronic throttle control 3) Manifold absolute pressure sensor 4) Mass air flow and intake air temperature sensor 5) Accelerator pedal position sensor 6) Oil temperature sensor 7) EGR valve 1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Electronic throttle control 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay 6) Engine coolant temperature sensor (*2) 7) Crankshaft position sensor (*3) 8) Camshaft position sensor (*3) 9) EGR valve 10) Engine torque control signal circuit 11) Ignition parts (*1) 12) Accelerator pedal position sensor 13) Oil temperature sensor

1) Manifold absolute pressure sensor 2) Mass air flow and intake air temperature sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5. Engine stalls, hesitates, or sputters at accelera- 5) Camshaft position sensor (*3) tion. 6) Purge control solenoid valve 7) Fuel injection parts (*4) 8) Electronic throttle control 9) Fuel pump and fuel pump relay 10) EGR valve

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General Diagnostic Table ENGINE (DIAGNOSTICS) Symptoms

6. Surging

7. Spark knock

8. After-burning in exhaust system

Problem parts 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5) Camshaft position sensor (*3) 6) Fuel injection parts (*4) 7) Electronic throttle control 8) Fuel pump and fuel pump relay 9) EGR valve 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor 4) Knock sensor 5) Fuel injection parts (*4) 6) Fuel pump and fuel pump relay 7) EGR valve 1) Mass air flow and intake air temperature sensor 2) Manifold absolute pressure sensor 3) Engine coolant temperature sensor (*2) 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay

*1: Check ignition coil and spark plug. *2: Indicate the symptom occurring only in cold temperatures. *3: Ensure the secure installation. *4: Check the fuel injector and fuel pressure regulator. *5: Inspect air leak in air intake system.

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GENERAL DESCRIPTION

GD(H6DO) 1. 2.

Page List of Diagnostic Trouble Code (DTC) ......................................................2 Diagnostic Trouble Code (DTC) Detecting Criteria ..................................10

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION

1. List of Diagnostic Trouble Code (DTC) A: LIST DTC P0011

P0014 P0016

P0017 P0018

P0019 P0021

P0024 P0030 P0031

P0032

P0037

P0038

P0050 P0051

P0052

P0057

P0058

P0068 P0101

Item Intake Camshaft Position - Timing Over-Advanced or System Performance (Bank 1) Exhaust AVCS System 1 (Range/ Performance) Crankshaft Position - Camshaft Position Correlation (Bank1)

Index

Crank and Cam Timing B System

Crankshaft Position - Camshaft Posi- Crank and Cam Timing B System

Exhaust AVCS System 2 (Range/

HO2S Heater Control Circuit (Bank 1 HO2S Heater Control Circuit Low

HO2S Heater Control Circuit High

HO2S Heater Control Circuit Low

HO2S Heater Control Circuit High

HO2S Heater Control Circuit (Bank 2 HO2S Heater Control Circuit Low

HO2S Heater Control Circuit High

HO2S Heater Control Circuit Low

HO2S Heater Control Circuit High

MAP/MAF - Throttle Position Correla- tion Mass or Volume Air Flow Circuit

GD(H6DO)-2

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0102 P0103 P0107

P0108

P0111

P0112 P0113 P0117 P0118 P0122

P0123

P0125

P0126

P0128

P0131 P0132 P0133

Item Mass or Volume Air Flow Circuit Low Input Mass or Volume Air Flow Circuit High Input Manifold Absolute Pressure/Barometric Pressure Circuit Low Input

Index

Manifold Absolute Pressure/Baro Intake Air Temperature Sensor 1 Cir- Intake Air Temperature Sensor 1 Cir- Intake Air Temperature Sensor 1 Cir- Engine Coolant Temperature Circuit Engine Coolant Temperature Circuit Throttle/Pedal Position Sensor/

Throttle/Pedal Position Sensor/

Insufficient Coolant Temperature for

Insufficient Engine Coolant Tempera- Coolant Thermostat (Engine Coolant O2 Sensor Circuit Low Voltage (Bank O2 Sensor Circuit High Voltage

O2 Sensor Circuit Slow Response

P0134

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)

P0137

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)

P0138 P0139

P0140

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)





GD(H6DO)-3

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0141 P0151 P0152 P0153

Item O2 Sensor Heater Circuit (Bank1 Sensor2) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 1) O2 Sensor Circuit High Voltage (Bank 2 Sensor 1) O2 Sensor Circuit Slow Response (Bank 2 Sensor 1)

P0154

O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 1)

P0157

O2 Sensor Circuit Low Voltage (Bank 2 Sensor 2) O2 Sensor Circuit High Voltage (Bank 2 Sensor 2) O2 Sensor Circuit Slow Response (Bank 2 Sensor 2)

P0158 P0159

P0160

O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 2)

P0161 P0171

O2 Sensor Heater Circuit (Bank2 Sensor2) System Too Lean (Bank 1)

P0172

System Too Rich (Bank 1)

P0174

System Too Lean (Bank 2)

P0175

System Too Rich (Bank 2)

P0181

Fuel Temperature Sensor “A” Circuit Range/Performance

P0182

Fuel Temperature Sensor “A” Circuit Low Input Fuel Temperature Sensor “A” Circuit High Input Engine Oil Temperature Sensor Circuit Range/Performance

P0183 P0196

P0197

Engine Oil Temperature Sensor Low

P0198

Engine Oil Temperature Sensor High

P0222

Throttle/Pedal Position Sensor/ Switch “B” Circuit Low

P0223

Throttle/Pedal Position Sensor/ Switch “B” Circuit High

P0230

Fuel Pump Primary Circuit

P0301

Cylinder 1 Misfire Detected

Index

















GD(H6DO)-4

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0302 P0303 P0304 P0305 P0306 P0327

P0328

P0332 P0333 P0335 P0336

P0340

P0345 P0365 P0390 P0400 P0420

P0442

P0447

P0448

P0451

P0452

Item Cylinder 2 Misfire Detected

Index

Cylinder 3 Misfire Detected

Cylinder 4 Misfire Detected

Cylinder 5 Misfire Detected

Cylinder 6 Misfire Detected

Knock Sensor 1 Circuit Low (Bank 1 Knock Sensor 1 Circuit High (Bank 1 Knock Sensor 2 Circuit Low (Bank 2) Knock Sensor 2 Circuit High (Bank 2) Crankshaft Position Sensor “A” Cir Crankshaft Position Sensor “A” Cir Camshaft Position Sensor “A” Circuit Camshaft Position Sensor “A” Circuit Camshaft Position Sensor “B” Circuit Camshaft Position Sensor “B” Circuit Exhaust Gas Recirculation Flow

Catalyst System Efficiency Below

Evaporative Emission Control Sys Evaporative Emission Control Sys Evaporative Emission Control Sys Evaporative Emission Control Sys

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P0453

Item Evaporative Emission Control System Pressure Sensor High Input

Index

P0456

Evaporative Emission Control System Leak Detected (Very Small Leak)

P0457

Evaporative Emission Control Sys Evaporative Emission System Purge Evaporative Emission System Purge Fuel Level Sensor “A” Circuit Range/ Fuel Level Sensor “A” Circuit Low

Fuel Level Sensor “A” Circuit High

Fuel Level Sensor Circuit Intermittent Vehicle Speed Sensor “A”

Idle Air Control System RPM Lower

Idle Air Control System RPM Higher

P0458

P0459

P0461

P0462 P0463 P0464 P0500 P0506

P0507

P0512

Starter Request Circuit

P0513

Incorrect Immobilizer Key

P0604

Internal Control Module Random Access Memory (RAM) Error

P0605

Internal Control Module Read Only Memory (ROM) Error

P0607

Throttle Control System Circuit Range/Performance

P0638

Throttle Actuator Control Range/Performance (Bank 1)

P0700

Transmission Control System (MIL Request) O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1)

P1152

P1153

O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1)







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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P1154

Item O2 Sensor Circuit Range/Performance (Low) (Bank 2 Sensor 1)

P1155

O2 Sensor Circuit Range/Performance (High) (Bank 2 Sensor 1)

P1160

Return Spring Failure

P1443

Vent Control Solenoid Valve Function Problem EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input)

P1492

P1493

EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input)

P1494

EGR Solenoid Valve Signal #2 Circuit Malfunction (Low Input)

P1495

EGR Solenoid Valve Signal #2 Circuit Malfunction (High Input)

P1496

EGR Solenoid Valve Signal #3 Circuit Malfunction (Low Input)

P1497

EGR Solenoid Valve Signal #3 Circuit Malfunction (High Input)

P1498

EGR Solenoid Valve Signal #4 Circuit Malfunction (Low Input)

P1499

EGR Solenoid Valve Signal #4 Circuit Malfunction (High Input)

P1518

Starter Switch Circuit Low Input

P1560

Back-Up Voltage Circuit Malfunction

P1570

Antenna

P1571

Reference Code Incompatibility

P1572 P1574

IMM Circuit Failure (Except Antenna Circuit) Key Communication Failure

P1576

EGI Control Module EEPROM

P1577

IMM Control Module EEPROM

P1578

Meter Failure

P1602

Control Module Programming Error

Index















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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P2088

Item Intake Camshaft Position Actuator Control Circuit Low (Bank 1)

P2089

Intake Camshaft Position Actuator Control Circuit High (Bank 1)

P2090

Exhaust Camshaft Position Actuator Control Circuit Low (Bank 1)

P2091

Exhaust Camshaft Position Actuator Control Circuit High (Bank 1)

P2092

Intake Camshaft Position Actuator Control Circuit Low (Bank 2)

P2093

Intake Camshaft Position Actuator Control Circuit High (Bank 2)

P2094

Exhaust Camshaft Position Actuator Control Circuit Low (Bank 2)

P2095

Exhaust Camshaft Position Actuator Control Circuit High (Bank 2)

P2096

Post Catalyst Fuel Trim System Too Lean (Bank 1)

P2097

Post Catalyst Fuel Trim System Too Rich (Bank 1)

P2098

Post Catalyst Fuel Trim System Too Lean (Bank 2)

P2099

Post Catalyst Fuel Trim System Too Rich (Bank 2)

P2101

Throttle Actuator Control Motor Circuit Range/Performance

P2102

Throttle Actuator Control Motor Circuit Low Throttle Actuator Control Motor Circuit High

P2103

P2109

Throttle/Pedal Position Sensor “A” Minimum Stop Performance

P2122

Throttle/Pedal Position Sensor/ Switch “D” Circuit Low Input

P2123

Throttle/Pedal Position Sensor/ Switch “D” Circuit High Input

P2127

Throttle/Pedal Position Sensor/ Switch “E” Circuit Low Input

Index













GD(H6DO)-8

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List of Diagnostic Trouble Code (DTC) GENERAL DESCRIPTION DTC P2128

Item Throttle/Pedal Position Sensor/ Switch “E” Circuit High Input

P2135

Throttle/Pedal Position Sensor/ Switch “A”/“B” Voltage Correlation

P2138

Throttle/Pedal Position Sensor/ Switch “D”/“E” Voltage Correlation

P2227

Atmospheric Pressure Sensor Range/Performance

P2228

Barometric Pressure Circuit Low

P2229

Barometric Pressure Circuit High

U0073

CAN Failure, Bus ‘OFF’ Detection

U0101

CAN (TCU) Data not Loaded

U0122

CAN (VDC) Data not Loaded

U0140

CAN (BCU) Data not Loaded

U0402

CAN (TCU) Data Abnormal

U0416

CAN (VDC) Data Abnormal

U0422

CAN (BCU) Data Abnormal

Index









GD(H6DO)-9

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

2. Diagnostic Trouble Code (DTC) Detecting Criteria A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the AVCS system malfunction. Judge NG when the amount of AVCS actual timing advance does not approach to the amount of AVCS target timing advance.

2. COMPONENT DESCRIPTION

(3) (1) (5) (2)

(4)

EN-01852

(1) (2)

AVCS timing controller Vane

(3) (4)

Engine control module (ECM) Oil flow control solenoid valve

(5)

Oil pressure

3. ENABLE CONDITION Secondary Parameters Time of establishing all secondary parameter conditions Battery voltage Engine speed Engine coolant temperature AVCS control Target timing advance change amount (per 64 ms)

Enable Conditions ≥ 2000 ms ≥ 10.9 V ≥ 1500 rpm ≥ 50 °C (122 °F) Operation < 1.07 °CA

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after warming up when the engine speed increases and AVCS operates.

GD(H6DO)-10

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD 1) When the conditions during which the differences of AVCS target timing advance amount and AVCS actual timing advance amount is large continues for certain amount of time. 2) When the differences of target timing advance amount and actual timing advance amount is calculated during AVCS control, and the difference per predetermined time is the specified value or larger. • Abnormality Judgment Judge as NG when the following conditions are established within the predetermined time. Judgment Value Malfunction criteria Σ(Target position – Actual position) or Σ(Target position – Actual position)

Threshold value > 15000 °CA (Bank 1) > 15000 °CA (Bank 2) < –4800 °CA (Bank 1) < –4800 °CA (Bank 2)

Time Needed for Diagnosis: 60000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established within the predetermined time. Judgment Value Malfunction criteria Σ(Target position – Actual position)

Threshold value ≤ 15000 °CA (Bank 1) ≤ 15000 °CA (Bank 2) and ≥ –4800 °CA (Bank 1) ≥ –4800 °CA (Bank 2)

Time Needed for Diagnosis: 60000 ms

GD(H6DO)-11

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

B: DTC P0014 EXHAUST AVCS SYSTEM 1 (RANGE/PERFORMANCE) 1. OUTLINE OF DIAGNOSIS Detect the exhaust AVCS system malfunction. Judge as NG when actual exhaust ABCS advance angle amount does not approach the target exhaust ABCS advance angle amount.

2. COMPONENT DESCRIPTION

(3) (1) (5) (2)

(4)

EN-01852

(1) (2)

Exhaust AVCS timing controller Vane

(3) (4)

Engine control module (ECM) Oil flow control solenoid valve

(5)

Oil pressure

3. ENABLE CONDITIONS Secondary Parameters Time of establishing all secondary parameter conditions Battery voltage Engine speed Engine coolant temperature Exhaust AVCS control Target timing advance change amount (per 64 ms)

Enable Conditions ≥ 2000 ms ≥ 10.9 V ≥ 1500 rpm ≥ 50 °C (122 °F) Operation < 1.07 °CA

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously when the exhaust AVCS is operating with high engine speed after warming up.

GD(H6DO)-12

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD 1) When the status where there is a large difference between the target exhaust AVCS advance angle amount and the actual exhaust AVCS advance angle amount continues for a constant period of time. 2) When the total value of every predetermined time is great after calculating the difference values between the target and actual advanced angle amount during the exhaust AVCS control. • Abnormality Judgment Judge as NG when the following conditions are established within the predetermined time. Judgment Value Malfunction Criteria Σ(Target position – Actual position) or Σ(Target position – Actual position)

Threshold Value > 8000 °CA (bank 1) > 8000 °CA (bank 2) < –4800 °CA (bank 1) < –4800 °CA (bank 2)

Time Needed for Diagnosis: 60000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established within the predetermined time. Judgment Value Malfunction Criteria Σ(Target position – Actual position)

Threshold Value ≤ 8000 °CA (bank 1) ≤ 8000 °CA (bank 2) and ≥ –4800 °CA (bank 1) ≥ –4800 °CA (bank 2)

Time Needed for Diagnosis: 60000 ms

GD(H6DO)-13

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

C: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK1) 1. OUTLINE OF DIAGNOSIS Detect the AVCS system malfunction. Judge as NG when standard timing advance amount is far from learning angle.

2. COMPONENT DESCRIPTION

(3) (1) (5) (2)

(4)

EN-01852

(1) (2)

AVCS timing controller Vane

(3) (4)

Engine control module (ECM) Oil flow control solenoid valve

(5)

Oil pressure

3. ENABLE CONDITION Secondary Parameters Battery voltage Engine speed

Engine coolant temperature AVCS control Target timing advance

Enable Conditions ≥ 10.9 V ≥ 525 rpm and < 800 rpm ≥ 75 °C (167 °F) Not in operation 0°CA

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting engine and while AVCS is not operating.

GD(H6DO)-14

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD Judge as NG when the absolute value of the difference between cam signal input position and learning value is out of specification. • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria |Crankshaft position when camshaft position sensor signal is input – Learning value|

Threshold Value > 12 °CA

Time Needed for Diagnosis: 20000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. NOTE: Initial standard learning value is the value of crank angle initially input at the production plant. And then it will be updated every time normal judgment has been completed. Learning value will not be updated if NG judgment occurs because timing belt or chain derails suddenly in process or because wrong assembly occurs during servicing. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria |Crankshaft position when camshaft position sensor signal is input – Learning value|

Threshold Value ≤ 12 °CA

Time Needed for Diagnosis: Less than 1 second

GD(H6DO)-15

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

D: DTC P0017 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the exhaust AVCS system malfunction. Judge as NG when standard timing advance amount is far from learning angle.

2. COMPONENT DESCRIPTION

(3) (1) (5) (2)

(4)

EN-01852

(1) (2)

Exhaust AVCS timing controller Vane

(3) (4)

Engine control module (ECM) Oil flow control solenoid valve

(5)

Oil pressure

3. ENABLE CONDITIONS Secondary Parameters Battery voltage Engine speed

Engine coolant temperature Exhaust AVCS control Target timing advance

Enable Conditions ≥ 10.9 V ≥ 525 rpm and < 800 rpm ≥ 75 °C (167 °F) Not in operation 0°CA

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously while the exhaust AVCS is not operating after warming up.

GD(H6DO)-16

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD Judge as NG when the absolute value of the difference between cam signal input position and learning value is out of specification. • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria |Crankshaft position when camshaft position sensor signal is input – Learning value|

Threshold Value > 12 °CA

Time Needed for Diagnosis: 20000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. NOTE: Initial standard learning value is the value of crank angle initially input at the production plant. And then it will be updated every time normal judgment has been completed. Learning value will not be updated if NG judgment occurs because timing belt or chain derails suddenly in process or because wrong assembly occurs during servicing. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria |Crankshaft position when camshaft position sensor signal is input – Learning value|

Threshold Value ≤ 12 °CA

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

E: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0016.

F: DTC P0019 CRANK AND CAM TIMING B SYSTEM FAILURE (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0017.

G: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0011.

H: DTC P0024 EXHAUST AVCS SYSTEM 2 (RANGE/PERFORMANCE) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0014.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

I:

DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

1. OUTLINE OF DIAGNOSIS Detect functional errors of the front oxygen (A/F) sensor heater. Judge as NG when it is determined that the front oxygen (A/F) sensor impedance is large when looking at engine status such as deceleration fuel cut.

2. COMPONENT DESCRIPTION

(1)

(2)

(3)

(4)

(5)

EN-07655

(1) (2)

Element cover (outer) Element cover (inner)

(3) (4)

Sensor element Ceramic heater

(5)

Sensor housing

3. ENABLE CONDITION Secondary Parameters Condition established time Battery voltage Heater current Control duty ≥ 35 % After fuel cut

Enable Conditions ≥ 30000 ms ≥ 10.9 V Permitted Experienced ≥ 20000 ms

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after 30000 ms or more have passed since the engine started.

GD(H6DO)-19

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Front oxygen (A/F) sensor impedance

Threshold value > 50 Ω

Time Needed for Diagnosis: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Front oxygen (A/F) sensor impedance

Threshold value ≤ 50 Ω

Time Needed for Diagnosis: 10000 ms

GD(H6DO)-20

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

J: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect front oxygen (A/F) sensor heater open or short circuit. The front oxygen (A/F) sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains Low.

2. COMPONENT DESCRIPTION

(A) OFF (B)

(D)

ON 0V

(C)

EN-01792

(A)

Battery voltage

(D)

Low error

(B)

Front oxygen (A/F) sensor heater output voltage

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H6DO)-21

(C)

128 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Front oxygen (A/F) sensor heater control duty

Threshold Value Low < 87.5 %

Time Needed for Diagnosis: 4 ms × 250 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

K: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect front oxygen (A/F) sensor heater open or short circuit. The front oxygen (A/F) sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains High.

2. COMPONENT DESCRIPTION

(A) (D)

OFF

(B)

ON 0V

(C)

EN-01793

(A)

Battery voltage

(D)

High error

(B)

Front oxygen (A/F) sensor heater output voltage

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H6DO)-23

(C)

128 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Front oxygen (A/F) sensor heater control duty

Threshold Value High ≥ 12.5 %

Time Needed for Diagnosis: 4 ms × 250 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value Low

Time Needed for Diagnosis: Less than 1 second

GD(H6DO)-24

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

L: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect the rear oxygen sensor heater open or short circuit. The rear oxygen sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains Low.

2. COMPONENT DESCRIPTION

(A) OFF (B)

ON

(D)

0V

(C)

EN-01792

(A)

Battery voltage

(D)

Low error

(B)

Output voltage of the rear oxygen sensor heater

(C)

256 ms (cycle)

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine Engine speed

Enable Conditions ≥ 10.9 V ≥ 1 second < 4500 rpm

4. GENERAL DRIVING CYCLE After starting the engine, perform the diagnosis continuously when engine is low speed.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Rear oxygen sensor heater control duty

Threshold Value Low < 75 %

Time Needed for Diagnosis: 8 ms × 1250 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

GD(H6DO)-26

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

M: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect the rear oxygen sensor heater open or short circuit. The rear oxygen sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the output terminal voltage at OFF is the battery voltage. Judge as NG when the terminal voltage remains High.

2. COMPONENT DESCRIPTION

(A) (D)

OFF

(B)

ON 0V

(C)

EN-01793

(A)

Battery voltage

(D)

High error

(B)

Output voltage of the rear oxygen sensor heater

(C)

256 ms (cycle)

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine Engine speed

Enable Conditions ≥ 10.9 V ≥ 1 second < 4500 rpm

4. GENERAL DRIVING CYCLE After starting the engine, perform the diagnosis continuously when engine is low speed.

GD(H6DO)-27

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage level Rear oxygen sensor heater control duty

Threshold Value High ≥ 15 %

Time Needed for Diagnosis:8 ms × 1250 time (s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage level

Threshold Value Low

Time Needed for Diagnosis: Less than 1 second

N: DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0030.

O: DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0031.

P: DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0032.

Q: DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0037.

R: DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0038.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

S: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION 1. OUTLINE OF DIAGNOSIS Detect problems in the intake manifold pressure sensor output properties. Judge as NG when the intake air pressure AD value is Low whereas it seemed to be High from the viewpoint of engine condition, or when it is High whereas it seemed to be Low from the engine condition.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(B)

(3)

EN-01765

(A)

Output voltage

(B)

Absolute pressure

(1)

Connector

(2)

Terminals

3. ENABLE CONDITION Secondary Parameters Engine coolant temperature

Enable Conditions ≥ 75 °C (167 °F)

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after idling.

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(3)

O-ring

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when Low side or High side becomes NG. If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load

Threshold Value < 2700 rpm ≥ 15 ° < 1.8 V > 1 g/rev (0.04 oz/rev) 500 rpm — 850 rpm < 4.3 ° ≥ 2.78 V < 0.6 g/rev (0.02 oz/rev)

Time Needed for Diagnosis: Low side: 3000 ms High side: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG when both Low side and High side become OK. If the duration of time while the following conditions are met is longer than the time indicated, judge as OK. Judgment Value Malfunction Criteria Low Engine speed Throttle position Output voltage Engine load High Engine speed Throttle position Output voltage Engine load

Threshold Value < 2700 rpm ≥ 15 ° ≥ 1.8 V > 1 g/rev (0.04 oz/rev) 500 rpm — 850 rpm < 4.3 ° < 2.78 V < 0.6 g/rev (0.02 oz/rev)

Time Needed for Diagnosis: Low side: Less than 1 s High side: Less than 1 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

T: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect the malfunction of air flow sensor output properties. Judge as a low side NG when the air flow voltage indicates a small value regardless of running in a state where the air flow voltage increases. Judge as a high side NG when the air flow voltage indicates a large value regardless of running in a state where the air flow voltage decreases. Judge air flow sensor property NG when the Low side or High side becomes NG.

2. COMPONENT DESCRIPTION

(1)

(3) (2)

(A)

(4)

EN-01766

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Voltage (V)

3. ENABLE CONDITION Secondary Parameters Engine coolant temperature

Enable Conditions ≥ 75 °C (167 °F)

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after idling.

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(4)

Amount of intake air (kg (lb)/s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when Low side or High side becomes NG. If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Low Output voltage Engine speed Throttle opening angle Intake manifold pressure High (1) Output voltage Engine speed Throttle opening angle Intake manifold pressure High (2) Output voltage Engine speed Throttle opening angle Intake manifold pressure Fuel system diagnosis

Threshold Value < 1.67 V ≥ 2000 rpm ≥ 15 ° ≥ 73.3 kPa (550 mmHg, 21.7 inHg) ≥ 1.83 V 500 rpm — 850 rpm < 4.5 ° ≥ 46.7 kPa (350 mmHg, 13.8 inHg) ≥ 1.67 V 500 rpm — 850 rpm < 4.5 ° ≥ 46.7 kPa (350 mmHg, 13.8 inHg) Rich side malfunction

Time Needed for Diagnosis: Low: 5000 ms High: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG when both Low side and High side become OK. Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Low Output voltage Engine speed Throttle opening angle Intake manifold pressure High Output voltage Engine speed Throttle opening angle Intake manifold pressure Fuel system diagnosis

Threshold Value ≥ 1.67 V ≥ 2000 rpm ≥ 15 ° ≥ 73.3 kPa (550 mmHg, 21.7 inHg) < 1.83 V 500 rpm — 850 rpm < 4.5 ° < 46.7 kPa (350 mmHg, 13.8 inHg) Rich side normal

Time Needed for Diagnosis: Low: Less than 1 s High: Less than 1 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

U: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect open or short circuits of the air flow sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3) (2)

(A)

(4)

EN-01766

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Voltage (V)

(4)

Amount of intake air (kg (lb)/s)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≤ 0.22 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value > 0.22 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

V: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect open or short circuits of the air flow sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3) (2)

(A)

(4)

EN-01766

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Voltage (V)

(4)

Amount of intake air (kg (lb)/s)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.78 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.78 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

W: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of intake manifold pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(B)

(3)

EN-01765

(A)

Output voltage

(B)

Absolute pressure

(1)

Connector

(2)

Terminals

(3)

O-ring

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≤ 0.573 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value > 0.573 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

X: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of intake manifold pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(B)

(3)

EN-01765

(A)

Output voltage

(B)

Absolute pressure

(1)

Connector

(2)

Terminals

(3)

O-ring

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.388 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.388 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Y: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect the malfunction of intake air temperature sensor output property. Judge as NG when the intake air temperature is not varied whereas it seemed to be varied from the viewpoint of engine condition.

2. COMPONENT DESCRIPTION

(1)

(3)

(2) (A) (4)

EN-01767

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Resistance value (Ω)

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(4)

Intake air temperature °C (°F)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Engine coolant temperature at engine starting Battery voltage Continuous time when the vehicle speed is less than 140 km/h (87 MPH) Engine coolant temperature Intake air amount sum value Number of experiences under conditions below • Continuous time when vehicle speed is less than 4 km/h (2.5 MPH) • Continuous time when vehicle speed is 40 km/h (24.9 MPH) or more and Establishing time of 1, 2 1. Intake air amount 2. Vehicle speed

Enable Conditions < 35 °C (95 °F) ≥ 10.9 V ≥ 600 s ≥ 75 °C (167 °F) ≥ Value of Map 1 ≥ 3 time(s) ≥ Value from Map 2 ≥ 15 s

≥ 15 s ≥ 10 g/s (0.35 oz/s) ≥ 4 km/h (2.5 MPH)

Map 1 Engine coolant temperature °C (°F) Intake air amount sum value (g (oz)/s)

–20 (–4) 50000 (1763.5)

–10 (14) 7400 (261)

0 (32) 6600 (232.78)

10 (50) 5800 (204.57)

–30 (–22)

0 (32)

10 (50)

20 (68)

250

40

32

24

20 (68) 5000 (176.35)

Map 2 Engine coolant temperature °C (°F) Continuous time (s) when vehicle speed is less than 4 km/h (2.5 MPH)

4. GENERAL DRIVING CYCLE Perform the diagnosis when the vehicle speed condition is met after warming up from a cold condition.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Output voltage difference between Max. and Min.

Threshold Value < 0.02 V(Equivalent to approximately 0.5°C (0.9°F) near 25°C)

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Output voltage difference between Max. and Min.

Threshold Value ≥ 0.02 V

Time Needed for Diagnosis: Less than 1 second

GD(H6DO)-39

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Z: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the intake air temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3)

(2) (A) (4)

EN-01767

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Resistance value (Ω)

(4)

Intake air temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.231 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.231 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AA:DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the intake air temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(3)

(2) (A) (4)

EN-01767

(A)

Air

(1) (2)

Air flow sensor Intake air temperature sensor

(3)

Resistance value (Ω)

(4)

Intake air temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.716 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.716 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AB:DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the engine coolant temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.275 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.275 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AC:DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the engine coolant temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.716 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.716 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AD:DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Sensor 1 input voltage

Threshold value ≤ 0.217 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Sensor 1 input voltage

Threshold value > 0.217 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AE:DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A” CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Sensor 1 input voltage

Threshold value ≥ 4.858 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Sensor 1 input voltage

Threshold value < 4.858 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AF:DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL 1. OUTLINE OF DIAGNOSIS Detect the malfunction of engine coolant temperature output property. Judge as NG when the engine coolant temperature does not rise in driving conditions where it should.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters Engine speed Battery voltage

Enable Conditions ≥ Value from Map ≥ 10.9 V

Map Engine coolant temperature °C (°F) Engine speed rpm

–40 (–40)

–30 (–22)

–20 (–4)

–10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

500

500

500

500

500

500

500

500

Engine coolant temperature °C (°F) Engine speed rpm

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100 (212)

110 (230)

500

500

500

500

500

500

500

500

4. GENERAL DRIVING CYCLE Perform the diagnosis only once after engine start.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG if the criteria below are met. Judgment Value Malfunction Criteria Engine coolant temperature Timer for diagnosis after engine start

Threshold Value < 20 °C (68 °F) ≥ Judgment value of timer after engine start

Timer for diagnosis after engine start a. Timer stop at fuel cut b. During the driving conditions except a) above, timer counts up as follows. 64 ms + TWCNT ms (at 64 ms) TWCNT is defined as follows, TWCNT = 0 at idle switch ON, TWCNT show on the following table at idle switch OFF.

Temperature °C (°F)

–20 (–4) –10 (14) 0 (32) 10 (50) 20 (68)

0 (0)

8 (5)

16 (9.9)

0 ms 0 ms 0 ms 0 ms 0 ms

37.136 ms 27.391 ms 17.646 ms 7.9012 ms 7.9012 ms

74.272 ms 54.782 ms 35.292 ms 15.802 ms 15.802 ms

Vehicle speed km/h (MPH) 24 (14.9) 32 (19.9) 111.41 ms 82.173 ms 52.938 ms 23.704 ms 23.704 ms

126.66 ms 99.65 ms 72.64 ms 45 ms 45 ms

40 (24.9)

48 (29.8)

56 (34.8)

141.91 ms 117.13 ms 92.341 ms 45 ms 45 ms

163.59 ms 135.96 ms 108.34 ms 50 ms 50 ms

185.26 ms 154.8 ms 124.33 ms 50 ms 50 ms

Judgment value of timer after engine starting t = 429523 ms – 28605 ms × Ti Ti : The lowest coolant temperature after engine start Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Engine coolant temperature

Threshold Value ≥ 20 °C (68 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AG:DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION 1. OUTLINE OF DIAGNOSIS Detect the malfunction of the engine coolant temperature sensor characteristics. Memorize the engine coolant temperature and fuel temperature at the last engine stop, and use them to judge as NG when the engine coolant temperature does not decrease when it should.

2. COMPONENT DESCRIPTION (1)

(A)

(B)

(2) EN-02917

(A)

Resistance value (kΩ)

(B)

Temperature °C (°F)

(1)

Connector

(2)

Thermistor element

3. ENABLE CONDITION Secondary Parameters Battery voltage Refueling from the last engine stop till the current engine start Fuel level Engine coolant temperature at the last engine stop

Enable Conditions ≥ 10.9 V None ≥ 15 2 (3.96 US gal, 3.3 Imp gal) ≥ 75 °C (167 °F)

4. GENERAL DRIVING CYCLE Perform the diagnosis only once after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Engine coolant temperature at the last engine stop — Minimum engine coolant temperature after the engine start Fuel temperature at the last engine stop — fuel temperature Intake air temperature — fuel temperature Fuel temperature

Threshold Value < 2.5 °C (36.5 °F)

≥ 5 °C (41 °F) < 2.5 °C (36.5 °F) < 35 °C (95 °F)

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Engine coolant temperature at the last engine stop — Minimum engine coolant temperature after the engine start

Threshold Value ≥ 2.5 °C (36.5 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AH:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE) 1. OUTLINE OF DIAGNOSIS Detect malfunctions of the thermostat function. Judge as NG when the engine coolant temperature is lower than the estimated engine coolant temperature and the difference between them is large. Judge as OK when the engine coolant temperature becomes to 75°C (167°F), and the difference is small, before judging NG.

2. COMPONENT DESCRIPTION (8)

(2)

(2)

(7)

(6)

(5)

(4)

(9)

(1) (3) EN-01692

(1) (2) (3)

Valve Spring Stopper

(4) (5) (6)

Piston Guide Rubber seal

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(7) (8) (9)

Stop ring Wax element Jiggle valve

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Estimate ambient temperature Thermostat malfunction diagnosis Engine coolant temperature at engine starting Estimated coolant temperature Engine coolant temperature (Estimated – Measured) Engine coolant temperature Vehicle speed

Threshold Value ≥ 10.9 V ≥ –7 °C (19.4 °F) Incomplete < 55 °C (131 °F) ≥ 75 °C (167 °F) ≤ 75 °C (167 °F) > 22 °C (71.6 °F) ≥ 20 km/h (12.4 MPH)

Time Needed for Diagnosis: 64 ms × 1 time(s) × 255 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Estimate ambient temperature Thermostat malfunction diagnosis Engine coolant temperature at engine starting Engine coolant temperature (Estimated – Measured) Engine coolant temperature

Threshold Value ≥ 10.9 V ≥ –7 °C (19.4 °F) Incomplete < 55 °C (131 °F) ≥ 75 °C (167 °F) ≤ 22 °C (71.6 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AI: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of sensor. Judge as NG, when the element voltage is out of the specified range.

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Input voltage (+) or Input voltage (–) or |Input voltage (+) – Input voltage (–)|

Threshold Value < 1.128 V < 0.23 V < 0.644 V

Time Needed for Diagnosis: Input voltage (+): 1000 ms Input voltage (–): 1000 ms |Input voltage (+) – Input voltage (–)|: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Input voltage (+) Input voltage (–) |Input voltage (+) – Input voltage (–)|

Threshold Value ≥ 1.128 V ≥ 0.23 V ≥ 0.644 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AJ:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of sensor. Judge as NG, when the element voltage is out of the specified range.

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Input voltage (+) or Input voltage (–)

Threshold Value > 3.589 V > 3.541 V

Time Needed for Diagnosis: Input voltage (+): 1000 ms Input voltage (–): 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Input voltage (+) Input voltage (–)

Threshold Value ≤ 3.589 V ≤ 3.541 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AK:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect the slow response of front oxygen (A/F) sensor. Front oxygen (A/F) sensor cover has some ventilation holes for exhaust gas. Clogged ventilation holes are diagnosed. When the holes are clogged, the A/F output variation becomes slow comparing with the actual A/F variation because oxygen which reaches the zirconia layer is insufficient. Therefore, if the sensor cover holes are clogged, the rich to lean judgment in the ECM is delayed when the actual change from rich to lean occurs. Judge as NG when the actual movement in comparison to the ECM control amount is slow.

(2)

(3)

(1) EN-01694

(1)

Cover

(2)

Zirconia

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(3)

Clogging

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Barometric pressure Closed loop control with main feedback Front oxygen (A/F) sensor impedance Elapsed time after starting the engine Engine coolant temperature Engine speed Vehicle speed Amount of intake air Engine load Learning value of EVAP conc. during purge Total time of operating canister purge

Enable Conditions ≥ 1024 ms ≥ 10.9 V > 75 kPa (563 mmHg, 22.2 inHg) Operation 0 Ω — 50 Ω ≥ 120000 ms ≥ 75 °C (167 °F) 1000 rpm — 2500 rpm 10 km/h — 120 km/h (6.2 MPH — 74.6 MPH) 10 g/s — 40 g/s (0.35 oz/s — 1.41 oz/s) < 0.02 g/rev (0 oz/rev) < 0.2 ≥ 19.9 s

4. GENERAL DRIVING CYCLE Perform diagnosis only once at a constant speed of 10 km/h — 120 km/h (6.2 MPH — 74.6 MPH) 120000 ms or more after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD Calculate faf difference and the λ value difference every 32 ms × 4 . Calculate the diagnosis value after calculating 820 time(s). • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria parafca = td2faf/td2lmd > 0.15 where, td2faf (N) = td2faf (n–1) + |d2faf (n)| td2lmd (N) = td2lmd (n–1) + |d2lmd (n)| add up to 32 ms × 4 × 820 time(s). d2faf (n) = (faf (n) – faf (n–1)) – (faf (n–1) – faf (n–2)) d2lmd (n) = (lmd (n) – lmd (n–1)) – (lmd (n–1) – lmd (n–2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds

Threshold Value

Time Needed for Diagnosis: 32 ms × 4 × 820 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria parafca = td2faf/td2lmd where, td2faf (N) = td2faf (n–1) + |d2faf (n)| td2lmd (N) = td2lmd (n–1) + |d2lmd (n)|

Threshold Value ≤ 0.15

add up to 32 ms × 4 × 820 time(s). d2faf (n) = (faf (n) – faf (n–1)) – (faf (n–1) – faf (n–2)) d2lmd (n) = (lmd (n) – lmd (n–1)) – (lmd (n–1) – lmd (n–2)) faf = main feedback compensation coefficient every 128 milliseconds lmd = output lambda every 128 milliseconds

Time Needed for Diagnosis: 32 ms × 4 × 820 time(s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AL:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1) 1. OUTLINE OF DIAGNOSIS Detect open circuits of the sensor. Judge as NG when the impedance of the element is large.

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1) (2)

Atmosphere Exhaust gas

(3)

ZrO2

(4)

Ceramic heater

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Time of heater control duty at 70 % or more Front oxygen (A/F) sensor impedance.

Threshold Value ≥ 10.9 V ≥ 30000 ms > 500 Ω

Time Needed for Diagnosis: 5000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Front oxygen (A/F) sensor impedance.

Threshold Value ≥ 10.9 V ≤ 500 Ω

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AM:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect continuity NG of the oxygen sensor. If the oxygen sensor voltage reading is not within the probable range considering the operating conditions, judge as NG.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Used for abnormality judgment Secondary Parameters

Enable Conditions

High Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Low (1) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Low (2) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Current continuation time of the rear oxygen sensor heater Low (3) Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature Amount of intake air Current continuation time of the rear oxygen sensor heater Fuel cut

Not in operation In operation < 7 time(s) Not in limit value ≥ 10.9 V ≥ 75 °C (167 °F) Not in operation In operation < 7 time(s) Not in limit value ≥ 10.9 V ≥ 75 °C (167 °F) ≥ 10 g/s (0.35 oz/s) Not in operation In operation < 7 time(s) Not in limit value ≥ 10.9 V ≥ 75 °C (167 °F) < 10 g/s (0.35 oz/s) ≥ 25000 ms Not in operation In operation < 7 time(s) Not in limit value ≥ 10.9 V ≥ 75 °C (167 °F) < 10 g/s (0.35 oz/s) ≥ 25000 ms Experienced

Used for normality judgment Secondary Parameters Secondary air system Closed loop control at the oxygen sensor Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Engine coolant temperature

Enable Conditions Not in operation In operation < 7 time(s) Not in limit value ≥ 10.9 V ≥ 75 °C (167 °F)

4. GENERAL DRIVING CYCLE After starting the engine, continuously perform the diagnosis with the same engine condition.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria High Sensor output voltage Low Sensor output voltage

Threshold Value

DTC P0138 P0158 P0137 P0157

> 1.2 V < 0.03 V

Time Needed for Diagnosis: High: 2500 ms Low (1): 20000 ms Low (2): 40000 ms Low (3): Value from Map Map Fuel cut time (s) Time Needed for Diagnosis (s)

0 40000

2000 40000

10000 60000

Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria High Sensor output voltage Low Sensor output voltage

Threshold Value ≤ 1.2 V ≥ 0.03 V

DTC P0138 P0158 P0137 P0157

Time Needed for Diagnosis: High: Less than 1 s Low (1): Less than 1 s Low (2): Less than 1 s Low (3): Less than 1 s

AN:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0137.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AO:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2) 1. OUTLINE OF DIAGNOSIS Detect the slow response of the oxygen sensor. Judge as NG if either the rich to lean response diagnosis or lean to rich response diagnosis is NG, and Judge as OK if both are OK. [Rich → lean diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to rich to lean. If the measured response time is larger than the threshold value, it is NG. If it is smaller, it is OK. Response time calculation is categorized in two by voltage difference. • Response time in small voltage difference: Intermediate • Response time in large voltage difference: Wide 2. Judge as NG when the oxygen sensor voltage is large (rich) even after deceleration fuel cut has occurred. [Lean → rich diagnosis response] 1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to lean to rich. If the measured response time is larger than the threshold value, it is NG. 2. Judge as NG when the oxygen sensor voltage remains small when recovering from a deceleration fuel cut. Diagnostic method Measure the response time of the output change of the oxygen sensor when the A/F ratio changes to rich to lean. And Judge as NG when the measured response time is larger than the threshold value.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Rich → lean diagnosis response Secondary Parameters Battery voltage A/F main feedback control condition Deceleration fuel cut time of 5000 ms or more (intermediate) Deceleration fuel cut time of 5000 ms or more (wide) After fuel cut

Estimated temperature of the rear oxygen sensor element

Number of deceleration fuel cut

Enable Conditions ≥ 10.9 V Complete Experienced

≥ 2000 ms (Intermediate) ≥ 2000 ms (Wide) ≥ 480 °C (896 °F) (Intermediate) ≥ 480 °C (896 °F) (Wide) ≥ 1 time(s)

4. GENERAL DRIVING CYCLE Perform diagnosis once during deceleration fuel cut from a constant and high speed driving, when rear oxygen sensor is warmed up sufficiently. (Pay attention to the oxygen sensor voltage for the timing of the deceleration.)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Intermediate When the oxygen sensor output voltage changes from 0.55 V (rich) to 0.15 V (lean), calculate the minimum response time for output change between 0.5 V and 0.2 V for the judgment criteria.

Diagnosis execution condition

(A) (B)

Rear oxygen sensor (V) (G) (C) (D) (E)

Fuel cut on deceleration (F) (H)

EN-05566

(A) (D) (G)

0.55 V 0.15 V Measure the response time.

(B) (E) (H)

0.5 V 0V Execute the malfunction judgment in 2000 ms from the recovery of fuel cut on deceleration.

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(C) (F)

0.2 V More than 5000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Wide When the oxygen sensor output voltage changes from 0.65 V (rich) to 0.05 V (lean), calculate the minimum response time for output change between 0.6 V and 0.1 V for the judgment criteria.

Diagnosis execution condition

(A) (B)

Rear oxygen sensor (V) (G) (C) (D) (E)

Fuel cut on deceleration (F) (H)

EN-05566

(A)

0.65 V

(B)

0.6 V

(C)

0.1 V

(D) (G)

0.05 V Measure the response time.

(E) (H)

0V Execute the malfunction judgment in 2000 ms from the recovery of fuel cut on deceleration.

(F)

More than 5000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment 1) Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut. Response time (diagnosis value) > threshold value → abnormal NOTE: Perform NG judgment only during fuel cut, when exhaust gas apparently changes from rich → lean. Even without deceleration fuel cut, judge as OK if the value is below the threshold. 2) Judge as NG when the oxygen sensor voltage at a deceleration fuel cut is large. Judge as NG when oxygen sensor voltage is large even after a long period of deceleration fuel cut has completed. Judgment value (Intermediate) Malfunction Criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V or Longest time over 0.55 V

Threshold Value > 491 ms

≥ 2000 ms

Judgment value (Wide) Malfunction Criteria Shortest time change from rich (0.6 V O2 output) to lean (0.1 V) when voltage reduces from 0.65 V to 0.05 V or Longest time over 0.65 V

Threshold Value > Value from Map

≥ 2000 ms

Map Estimated temperature of rear oxygen sensor element when fuel cut starts °C (°F) Longest time in rich status after fuel cut (ms)

0 (32)

480 (896)

500 (932)

1000 (1832)

3000

3000

2000

2000

Time Needed for Diagnosis: 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Normality Judgment 1) Regardless of a deceleration fuel cut, if the response time (diagnosis value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as a normal condition. Response time (diagnosis value) ≤ threshold value → normal 2) Do not judge as a normal condition. Judge as OK and clear the NG if the following conditions are established.

Judgment value (Intermediate) Malfunction Criteria Shortest time change from rich (0.5 V O2 output) to lean (0.2 V) when voltage reduces from 0.55 V to 0.15 V

Threshold Value ≤ 491 ms

Judgment value (Wide) Malfunction Criteria Shortest time change from rich (0.6 V O2 output) to lean (0.1 V) when voltage reduces from 0.65 V to 0.05 V

Threshold Value ≤ 2000 ms

Time Needed for Diagnosis: 1 time(s)

6. ENABLE CONDITION Lean → rich response diagnosis Secondary Parameters Battery voltage A/F main feedback control condition Deceleration fuel cut time is 5000 ms or more. After fuel cut Number of deceleration fuel cut

Enable Conditions ≥ 10.9 V Complete Experienced ≥ 2000 ms ≥ 1 time(s)

7. GENERAL DRIVING CYCLE Perform diagnosis once during deceleration fuel cut from a constant and high speed driving, when rear oxygen sensor is warmed up sufficiently. (Pay attention to the oxygen sensor voltage for the timing of the deceleration.)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

8. DIAGNOSTIC METHOD When the oxygen sensor output voltage changes from 0.25 V (lean) to 0.55 V (rich), calculate the minimum response time for output change between 0.3 V and 0.5 V for the judgment criteria.

Diagnosis execution condition

(H)

(A) (B)

Rear oxygen sensor (V)

(C) (D) (E)

(J)

(G) Fuel cut on deceleration (F) (I)

EN-05567

(A) (D) (G)

0.55 V 0.25 V More than 120000 ms

(J)

Judge NG when the voltage of rear oxygen sensor is 0.25 V or less for 120000 ms or more after recovery of fuel cut on deceleration.

(B) (E) (H)

0.5 V 0V Measure the response time (diagnostic value).

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(C) (F) (I)

0.3 V More than 5 seconds Execute the malfunction judgment in 4000 ms from the recovery of fuel cut on deceleration.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment 1) Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut. Response time (diagnosis value) > threshold value → abnormal 2) If the oxygen sensor voltage is small after recovering from a deceleration fuel cut, and remains small, judge as NG. Judgment Value Malfunction Criteria Shortest time change from lean (0.3 V O2 output) to rich (0.5 V) when voltage changes from 0.25 V to 0.55 V or Longest time under 0.25 V

Threshold Value > 4000 ms

≥ 120000 ms

Time Needed for Diagnosis: 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment 1) Regardless of a deceleration fuel cut, if the response time (diagnosis value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as a normal condition. Response time (diagnosis value) ≤ threshold value → normal 2) Do not judge as a normal condition. Judge as OK and clear the NG if the following conditions are established.

Judgment Value Malfunction Criteria Shortest time change from lean (0.3 V O2 output) to rich (0.5 V) when voltage changes from 0.25 V to 0.55 V

Threshold Value ≤ 4000 ms

Time Needed for Diagnosis: 1 time(s)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AP:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK1 SENSOR2) 1. OUTLINE OF DIAGNOSIS Detect the rear oxygen sensor open or short circuit. Judge as NG when the rear oxygen sensor voltage can be determined to be abnormal considering conditions such as intake air amount, engine coolant temperature, main feedback control and deceleration fuel cut.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

3. ENABLE CONDITION (USED ONLY FOR MALFUNCTION JUDGMENT) Secondary Parameters Closed loop control at the rear oxygen sensor Target output voltage of rear oxygen sensor Amount of intake air Engine coolant temperature Misfire detection every 200 rotations Front oxygen (A/F) sensor compensation coefficient Battery voltage Deceleration fuel cut of 5000 ms or more.

Enable Conditions In operation ≥ 0.55 V + 0.05 V ≥ 10 g/s (0.35 oz/s) ≥ 75 °C (167 °F) < 7 time(s) Not in limit value ≥ 10.9 V Experienced

4. GENERAL DRIVING CYCLE Perform the diagnosis once after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Minimum output voltage or Maximum output voltage

Threshold Value > 0.15 V < 0.55 V

Time Needed for Diagnosis: 200000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Threshold Value Diagnosis of the rear oxygen sensor volt- Incomplete age low side Minimum output voltage ≤ 0.15 V Maximum output voltage ≥ 0.55 V

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AQ:DTC P0141 O2 SENSOR HEATER CIRCUIT (BANK1 SENSOR2) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of rear oxygen sensor heater. While observing the engine condition, judge as NG if the rear oxygen sensor impedance is great.

2. COMPONENT DESCRIPTION

(1)

(2)

(3)

(4)

(5)

EN-07655

(1) (2)

Element cover (outer) Element cover (inner)

(3) (4)

Sensor element Ceramic heater

(5)

Sensor housing

3. ENABLE CONDITIONS Secondary Parameters Battery voltage Elapsed time after starting the engine Engine coolant temperature A/F sensor element impedance A/F sensor heater control duty Rear oxygen sensor heater control duty

Enable Conditions ≥ 10.9 V ≥ 1000 ms ≥ 75 °C (167 °F) ≤ 50 Ω ≤ 75 % < 70 %

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously 1000 ms or more after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output terminal for heater characteristics fault detection

Threshold Value Low

Time Needed for Diagnosis: 4 ms × 2500 time (s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output terminal for heater characteristics fault detection

Threshold Value High

Time Needed for Diagnosis: 4 ms × 2500 time (s)

AR:DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0131.

AS:DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0132.

AT:DTC P0153 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0133.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

AU:DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0134.

AV:DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0137.

AW:DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0137.

AX:DTC P0159 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0139.

AY:DTC P0160 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK2 SENSOR2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0140.

AZ:DTC P0161 O2 SENSOR HEATER CIRCUIT (BANK2 SENSOR2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0141.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BA:DTC P0171 SYSTEM TOO LEAN (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect fuel system malfunction by the amount of main feedback control. Diagnostic method Fuel system is diagnosed by comparing the target air fuel ratio calculated by ECM with the actual air fuel ratio measured by sensor.

2. ENABLE CONDITION Secondary Parameters A/F main learning system Engine coolant temperature Engine load change Engine load

Enable Conditions In operation ≥ 75 °C (167 °F) < 0.02 g/rev (0 oz/rev) ≥ Value of Map 1

Map 1 Engine speed (rpm)

Idling

700

1000

1500

2000

2500

3000

3500

4000

4500

5000

na

0.357 (0.01)

0.25 (0.01)

0.25 (0.01)

0.317 (0.01)

0.326 (0.01)

0.337 (0.01)

0.397 (0.01)

0.439 (0.02)

0.454 (0.02)

0.454 (0.02)

Measured value (g (oz)/rev)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment Compare the diagnosed value (fsobd) with the threshold value, and if a condition meeting the malfunction criteria below continues for 10 s × 10 time(s) or more, judge that there is a fault in the fuel system. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf In this case: sglmd = measured lambda

Threshold Value ≥ Value from Map 2

tglmda = target lambda faf = Main feedback compensation coefficient (every 64 ms) flaf = main feedback learning compensation coefficient

Map 2 Amount of air (g (oz)/s) fsobdL1 (%)

0 (0) 1.4

3.2 (0.11) 1.4

6.4 (0.23) 1.332

9.6 (0.34) 1.265

12.8 (0.45) 1.265

16 (0.56) 1.265

19.2 (0.68) 1.265

Time Needed for Diagnosis: 10 s × 10 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf

Threshold Value < 1.2

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BB:DTC P0172 SYSTEM TOO RICH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect fuel system malfunction by the amount of main feedback control. Diagnostic method Fuel system is diagnosed by comparing the target air fuel ratio calculated by ECM with the actual air fuel ratio measured by sensor.

2. ENABLE CONDITION Secondary Parameters A/F main learning system Engine coolant temperature Engine load change Learning value of EVAP conc. Cumulative time of canister purge after engine start Continuous period after canister purge starting Engine load

Enable Conditions In operation ≥ 75 °C (167 °F) ≤ 0.02 g/rev (0 oz/rev) < 0.1 ≥ 20 s ≥ 29884 ms ≥ Value of Map 1

Map 1 Engine speed (rpm)

Idling

700

1000

1500

2000

2500

3000

3500

4000

4500

5000

na

0.357 (0.01)

0.25 (0.01)

0.25 (0.01)

0.317 (0.01)

0.326 (0.01)

0.337 (0.01)

0.397 (0.01)

0.439 (0.02)

0.454 (0.02)

0.454 (0.02)

Measured value (g (oz)/rev)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment Compare the diagnosed value (fsobd) with the threshold value, and if a condition meeting the malfunction criteria below continues for 10 s × 10 time(s) or more, judge that there is a fault in the fuel system. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf In this case: sglmd = measured lambda tglmda = target lambda faf = Main feedback compensation coefficient (every 64 ms) flaf = main feedback learning compensation coefficient

Threshold Value < Value of Map 2

Map 2 Amount of air (g (oz)/s) fsobdL1 (%)

0 (0) 0.595

3.2 (0.11) 0.595

6.4 (0.23) 0.688

9.6 (0.34) 0.715

12.8 (0.45) 0.725

16 (0.56) 0.735

19.2 (0.68) 0.735

Time Needed for Diagnosis: 10 s × 10 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK when the malfunction criteria below are met for 10 seconds. Judgment Value Malfunction Criteria fsobd = (sglmd – tglmda) + faf + flaf

Threshold Value ≥ 0.8

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BC:DTC P0174 SYSTEM TOO LEAN (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0171.

BD:DTC P0175 SYSTEM TOO RICH (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0172.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BE:DTC P0181 FUEL TEMPERATURE SENSOR “A” CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect faults in the fuel temperature sensor output properties. Diagnosis is performed in two methods (drift diagnosis and stuck diagnosis). If either is NG, judge as NG. If both are OK, Judge as OK and clear the NG. Drift Diagnosis Normally fuel temperature is lower than engine coolant temperature. When the fuel temperature becomes higher than the engine coolant temperature, the range is considered to be shifted, and judged as NG. Stuck Diagnosis As the engine warms up (cumulative amount of intake air after starting is large), if the fuel temperature which should rise does not, determine as being stuck and NG.

2. COMPONENT DESCRIPTION

(A)

(B)

EN-01700

(A)

Resistance value (Ω)

(B)

Fuel temperature °C (°F)

3. ENABLE CONDITION DRIFT DIAGNOSIS Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Fuel level Elapsed time after starting the engine Engine coolant temperature – Engine coolant temperature at engine start Fuel temperature – Engine coolant temperature Battery voltage

Threshold Value ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) ≥ 20 s > 10 °C (50 °F) ≥ 10 °C (50 °F) ≥ 10.9 V

Time Needed for Diagnosis: 120 s Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Fuel level Elapsed time after starting the engine Engine coolant temperature – Engine coolant temperature at engine start Fuel temperature – Engine coolant temperature Battery voltage Engine coolant temperature

Threshold Value ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) ≥ 20 s > 10 °C (50 °F) < 10 °C (50 °F) ≥ 10.9 V < 75 °C (167 °F)

Time Needed for Diagnosis: Less than 1 second

6. ENABLE CONDITION Stuck Diagnosis Secondary Parameters Elapsed time after starting the engine Battery voltage

Enable Conditions ≥ 20000 ms ≥ 10.9 V

7. GENERAL DRIVING CYCLE Perform the diagnosis continuously 20 seconds after starting engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

8. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Accumulated amount of intake air Fuel temperature difference between Max. and Min.

Threshold Value ≥ 551043 g (19435.29 oz) < 2 °C (35.6 °F)

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Fuel temperature difference between Max. and Min.

Threshold Value ≥ 2 °C (35.6 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BF:DTC P0182 FUEL TEMPERATURE SENSOR “A” CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A)

(B)

EN-01700

(A)

Resistance value (Ω)

(B)

Fuel temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value < 0.573 V ≥ 10.9 V

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value ≥ 0.573 V ≥ 10.9 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BG:DTC P0183 FUEL TEMPERATURE SENSOR “A” CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel temperature sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A)

(B)

EN-01700

(A)

Resistance value (Ω)

(B)

Fuel temperature °C (°F)

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value ≥ 4.694 V ≥ 10.9 V

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage Battery voltage

Threshold Value < 4.694 V ≥ 10.9 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BH:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect for abnormal values in the oil temperature sensor output properties. Judge as NG when the oil temperature does not rise even though the engine is running under a condition where it should rise.

2. ENABLE CONDITION Secondary Parameters Battery voltage Engine speed

Enable Conditions ≥ 10.9 V ≥ Value from Map

Map Engine coolant temperature °C (°F) Engine speed rpm

–40 (–40)

–30 (–22)

–20 (–4)

–10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

500

500

500

500

500

500

500

500

Engine coolant temperature °C (°F) Engine speed rpm

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100 (212)

110 (230)

500

500

500

500

500

500

500

500

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Engine oil temperature After engine start oil temperature sensor characteristic diagnosis timer.

Threshold Value < 50 °C (122 °F) ≥ Judgment value for after engine start oil temperature sensor characteristic diagnosis timer

After engine start oil temperature sensor characteristic diagnosis timer (timer for diagnosis). a. Timer stop at fuel cut b. During the driving conditions except a) above, timer counts up as follows. 64 ms + TOILCNT ms (at 64 ms) Where, TOILCNT is determined as follows, TOILCNT = 0 at idle switch ON For TOILCNT at Idle switch off, refer to the following table.

Temperature °C (°F)

–40 (–40) –30 (–22) –20 (–4) –10 (14) 0 (32)

0 (0) 0 ms 0 ms 0 ms 0 ms 0 ms

8 (5) 32 ms 93 ms 123 ms 166 ms 187 ms

16 (9.9) 76 ms 121 ms 148 ms 187 ms 212 ms

Vehicle speed km/h (MPH) 24 (14.9) 32 (19.9) 40 (24.9) 130 ms 149 ms 171 ms 157 ms 170 ms 184 ms 184 ms 193 ms 204 ms 208 ms 223 ms 239 ms 243 ms 252 ms 262 ms

48 (29.8) 176 ms 193 ms 214 ms 242 ms 266 ms

56 (34.8) 181 ms 203 ms 226 ms 245 ms 270 ms

After engine start oil temperature characteristic diagnosis timer judgment value (t). t = 3600000 ms – 60000 ms × Ti (t ≥ 2400000) Ti = The lowest coolant temperature after starting the engine. Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Engine oil temperature

Threshold Value ≥ 50 °C (122 °F)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BI: DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the oil temperature sensor. Judge as NG when outside of the judgment value.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.188 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.188 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BJ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the oil temperature sensor. Judge as NG when outside of the judgment value.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.694 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.694 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BK:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Sensor 2 input voltage

Threshold value ≤ 0.926 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Sensor 2 input voltage

Threshold value > 0.926 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BL:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH “B” CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of throttle position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

(4)

Engine control module (ECM)

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Sensor 2 input voltage

Threshold value ≥ 4.858 V

Time Needed for Diagnosis: 24 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Sensor 2 input voltage

Threshold value < 4.858 V

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BM:DTC P0230 FUEL PUMP PRIMARY CIRCUIT 1. OUTLINE OF DIAGNOSIS Detect the malfunction of fuel pump control unit. Judge as NG when the NG signal is sent through a diagnostic line coming from the fuel pump control unit. Fuel pump control unit detects the open or short circuit malfunction for each line, and then sends NG signals if one of them is found NG.

2. COMPONENT DESCRIPTION

+B FP+

FPC (1)

(3)

(2) DI

(4)

FP-

E

E EN-01771

(1) (2)

Engine control module (ECM) Fuel pump control unit

(3)

Fuel pump

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H6DO)-91

(4)

Battery

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Fuel pump control Fuel pump control unit output diagnosis signal Fuel level

Threshold Value ≥8V ≥ 180000 ms ON Low ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal)

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Fuel pump control Fuel pump control unit output diagnosis signal Fuel level

Threshold Value ≥8V ≥ 180000 ms ON High ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BN:DTC P0301 CYLINDER 1 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS Detect the presence of misfire occurrence. (Revolution fluctuation method) Monitoring Misfire which influences exhaust deterioration (1.5 times of FTP) and catalyst damage is made obligatory by the law. Misfire affecting these two has two patterns below. : • Intermittent misfire (The same cylinder misfires in random, or different cylinders misfire in random.): FTP 1.5 times misfire • Every time misfire (The same cylinder misfires every time.): FTP 1.5 times misfire, Catalyst damage misfire The following detecting methods are adopted for these detection. 1) Intermittent misfire: FTP 1.5 times misfire • 120° Interval Difference Method • 360° Interval Difference Method (whole range) • 720° Interval Difference Method (3,000 rpm or more) 2) Misfire every time: FTP 1.5 times misfire, Catalyst damage misfire • 360° Interval Difference Method

2. ENABLE CONDITION Secondary Parameters All secondary parameters enable conditions Intake manifold pressure change at 120° CA Throttle position variation for 16 ms Fuel shut-off function Fuel level Vehicle dynamic control or AT torque control Evaporative system leak check Engine speed Intake manifold pressure Battery voltage Fuel parameter determination Elapsed time after starting the engine Engine speed variation for 32 ms

Enable Conditions ≥ 1024 ms < Value of Map 1 < 20 ° Not in operation ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) Not in operation Not in operation 450 rpm — 6500 rpm ≥ Value from Map 2 ≥8V Not extremely low volatility ≥ 0 ms < 500 rpm

Map 1 rpm kPa (mmHg, inHg)

700

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

7000

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

20 (150, 5.9)

700

1000

1500

2000

2500

3000

3500

4000

Map 2 rpm kPa (mmHg, inHg)

4500 5000 5500 6000 6500 7000 28.7 30.6 32.4 34.3 36.4 36.4 30.3 28 25.9 27.7 25.4 27 29 28.3 (227.6 , (209.9 , (194.0 , (207.8 , (190.2 , (202.9 , (217.9 , (212.5 , (215.3 , (229.3 , (243.3 , (257.3 , (273.3 , (273.3 , 8.4) 8.5) 9) 9.6) 10.1) 10.8) 10.8) 9) 8.3) 7.6) 8.2) 7.5) 8) 8.6)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. GENERAL DRIVING CYCLE • If conditions are met, it is possible to detect the misfires from idling to high engine speed. However, to avoid excessive load or harm to the engine, perform diagnosis at idle. • Perform the diagnosis continuously.

4. DIAGNOSTIC METHOD When a misfire occurs, the engine speed will decreased and the crankshaft position speed will change. Calculate the interval difference value (diagnostic value) from crankshaft position speed by the following formula, and judge whether a misfire is occurring or not comparing the calculated result with judgment value. Counting the number of misfires. If the misfire ratio is higher during 1000 revs. or 200 revs., Judge corresponding cylinders as NG. Diagnostic value calculation (Calculate from angle speed) →

Misfire detection every single ignition NG judgment (Misfire occurrence judg(Compare diagnostic value with judg- ment required by the law) (Compare ment value) → number of misfire with judgment) • 120° Interval Difference Method • 360° Interval Difference Method • 720° Interval Difference Method

• FTP 1.5 times misfire NG judgment • Catalyst damage misfire NG judgment

As shown in the following figure, pick a cylinder as the standard and name it omg 0. And the former crankshaft position speed is named omg 1, the second former crankshaft position speed is named omg 2, the third is named omg 3, etc.

(A)

(B)

#1

#6

#3

#2

#5

#4

#1

#6

#3

omg7

omg6

omg5

omg4

omg3

omg2

omg1

omg0

#2

EN-02184

(A)

Ignition order

(B)

Crankshaft position speed

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

120° Interval Difference Method Diagnostic domg 120 = (omg 1 – omg 0) – (omg 7 – omg 1)/6 value Judge as a misfire in the following cases. • domg 120 > judgment value of positive side • domg 121 ≤ judgment value of negative side (Judgment value before 120° CA)

domg120 Threshold value (positive number)

domg120

Threshold value (negative number)

Judged as misfire

EN-02185

360° Interval Difference Method Diagnostic value Misfire judgment

domg 360 = (omg 1 – omg 0) – (omg 4 – omg 3) domg 360 > Judgment value → Judge as misfire

domg360 Threshold value

domg360

Judged as misfire

EN-02279

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

720° Interval Difference Method Diagnostic value Misfire judgment

domg 720 = (omg 1 – omg 0) – (omg 7 – omg 6) domg 720 > Judgment value → Judge as misfire

domg720

Threshold value

domg720

Judged as misfire

EN-02280

• FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas) • Abnormality Judgment Judgment Value (Judge that malfunction occurs when the misfire ratio is high in 1000 engine revs.) Malfunction Criteria FTP emission judgment value

Threshold Value ≥ 40 × 100/3000% in 1000 revs.

Time Needed for Diagnosis: 1000 engine revs. Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judgment Value Malfunction Criteria FTP emission judgment value

Threshold Value < 40 × 100/3000% in 1000 revs.

Time Needed for Diagnosis: 1000 engine revs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Catalyst damage misfire (Misfire occurrence level damaging catalyst) • Abnormality Judgment Judgment Value Malfunction Criteria Catalyst damage misfire judgment value

Threshold Value ≥ Value of Map 3

Map 3

Engine speed (rpm)

700 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000

0.2 (0.01)

0.4 (0.01)

0.6 (0.02)

0.8 (0.03)

90 90 89 88 88 64 50 40 50 40 40 36 32 32

90 90 88 84 80 56 40 38 30 30 30 36 32 32

88 88 80 64 56 30 30 30 30 30 30 30 30 30

76 76 64 40 36 30 30 30 30 30 30 30 30 30

Intake air (g(oz)/rev) 1 1.2 (0.04) (0.04) 68 68 56 36 30 30 30 30 30 30 30 30 30 30

68 68 56 35 30 30 30 30 30 30 30 30 30 30

1.4 (0.05)

1.6 (0.06)

1.8 (0.06)

2 (0.07)

68 68 56 35 30 30 30 30 30 30 30 30 30 30

68 68 56 35 30 30 30 30 30 30 30 30 30 30

68 68 56 35 30 30 30 30 30 30 30 30 30 30

68 68 56 35 30 30 30 30 30 30 30 30 30 30

Time Needed for Diagnosis: 200 engine revs. Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judgment Value Malfunction Criteria Catalyst damage misfire judgment value

Threshold Value < Value of Map 2

Time Needed for Diagnosis: 200 engine revs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BO:DTC P0302 CYLINDER 2 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

BP:DTC P0303 CYLINDER 3 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

BQ:DTC P0304 CYLINDER 4 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

BR:DTC P0305 CYLINDER 5 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

BS:DTC P0306 CYLINDER 6 MISFIRE DETECTED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0301.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BT:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of knock sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(4)

(5)

(2)

(A)

(3)

EN-01707

(A)

To knock sensor harness

(1) (2)

Case Weight

(3) (4)

Piezoelectric element Nut

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H6DO)-99

(5)

Resistance

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 0.243 V

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 0.243 V

Time Needed for Diagnosis: Less than 1 second

GD(H6DO)-100

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BU:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of knock sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(1)

(4)

(5)

(2)

(A)

(3)

EN-01707

(A)

To knock sensor harness

(1) (2)

Case Weight

(3) (4)

Piezoelectric element Nut

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H6DO)-101

(5)

Resistance

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.709 V

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.709 V

Time Needed for Diagnosis: Less than 1 second

BV:DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0327.

BW:DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0328.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BX:DTC P0335 CRANKSHAFT POSITION SENSOR “A” CIRCUIT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the crankshaft position sensor. Judge as NG when the crank signal is not input even though the starter was rotated.

2. COMPONENT DESCRIPTION

Number of camshaft signal - 3 is normal at two engine revolution in a range of 0 CA - 0 CA. (A)

(B)

#1BTDC10 CA

#6BTDC10 CA

#3BTDC10 CA

#2BTDC10 CA

#5BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(C)

10 CA

30 CA

30 CA

EN-03092

(A)

Camshaft signal (RH)

(B)

Camshaft signal (LH)

(C)

Crankshaft signal

(1)

(3)

(2)

(1)

Crankshaft position sensor

EN-02188

(2)

Crank sprocket

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

GD(H6DO)-103

(3)

Crankshaft half-turn

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Starter switch Crankshaft position sensor signal Battery voltage

Threshold Value ON Not detected ≥8V

Time Needed for Diagnosis: 3000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Crankshaft position sensor signal Battery voltage

Threshold Value Input exists ≥8V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BY:DTC P0336 CRANKSHAFT POSITION SENSOR “A” CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect for faults in crankshaft position sensor output properties. Judge as NG when there is a problem in the number of crankshaft signals for every revolution.

2. COMPONENT DESCRIPTION

Number of camshaft signal - 3 is normal at two engine revolution in a range of 0 CA - 0 CA. (A)

(B)

#1BTDC10 CA

#6BTDC10 CA

#3BTDC10 CA

#2BTDC10 CA

#5BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(C)

10 CA

30 CA

30 CA

EN-03092

(A)

Camshaft signal (RH)

(B)

Camshaft signal (LH)

(C)

Crankshaft signal

(1)

(3)

(2)

(1)

Crankshaft position sensor

EN-02188

(2)

Crank sprocket

3. ENABLE CONDITION Secondary Parameters Battery voltage Engine speed

Enable Conditions ≥8V < 3000 rpm

GD(H6DO)-105

(3)

Crankshaft half-turn

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously under 3000 rpm engine speed.

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Cylinder number identification Amount of crank sensor signal during 1 rev.

Threshold Value Completed Not = 30

Time Needed for Diagnosis: 10 engine revs. Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Cylinder number identification Amount of crank sensor signal during 1 rev.

Threshold Value Completed = 30

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

BZ:DTC P0340 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 1 OR SINGLE SENSOR) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the camshaft position sensor. Judge as NG when the number of camshaft signals remains abnormal.

2. COMPONENT DESCRIPTION

Number of camshaft signal - 3 is normal at two engine revolution in a range of 0 CA - 0 CA. (A)

(B)

#1BTDC10 CA

#6BTDC10 CA

#3BTDC10 CA

#2BTDC10 CA

#5BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(C)

10 CA

30 CA

30 CA

EN-03092

(A)

Camshaft signal (RH)

(B)

Camshaft signal (LH)

(C)

Crankshaft signal

(1)

(3) (4)

(2)

EN-02190

(1)

Throttle

(2)

Camshaft plate

(3)

Detecting point

3. ENABLE CONDITION Secondary Parameters Battery voltage

Enable Conditions ≥8V

GD(H6DO)-107

(4)

Camshaft one revolution (engine two revolutions)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment 1 Judge as NG when the condition where the number of camshaft position sensor signals are less than 3 times during 2 engine revs continues. Judgment Value Malfunction Criteria Amount of camshaft sensor signal during 2 revs.

Threshold Value < 3 time(s)

Time Needed for Diagnosis: Engine two revolutions × 4 time(s) Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment 1 Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Camshaft position sensor signal

Threshold Value ≥ 3 time(s)

Time Needed for Diagnosis: Two engine revolutions • Abnormality Judgment 2 If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Starter Camshaft position sensor signal

Threshold Value ON No input

Time Needed for Diagnosis: 3000 ms • Normality Judgment 2 Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Camshaft position sensor signal

Threshold Value Input exists

Time Needed for Diagnosis: Less than 1 second

CA:DTC P0345 CAMSHAFT POSITION SENSOR “A” CIRCUIT (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0340.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CB:DTC P0365 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the camshaft position sensor. Judge as NG when the number of camshaft signals remains abnormal.

2. COMPONENT DESCRIPTION

Number of camshaft signal - 3 is normal at two engine revolution in a range of 0 CA - 0 CA. (A)

(B)

#1BTDC10 CA

#6BTDC10 CA

#3BTDC10 CA

#2BTDC10 CA

#5BTDC10 CA

#4BTDC10 CA

#1BTDC10 CA

(C)

10 CA

30 CA

30 CA

EN-03092

(A)

Cam signal (RH)

(B)

Cam signal (LH)

(C)

Crankshaft signal

(1)

(3) (4)

(2)

EN-02190

(1)

Throttle

(2)

Camshaft plate

(3)

Detecting point

3. ENABLE CONDITIONS Secondary Parameters Battery voltage

Enable Conditions ≥8V

GD(H6DO)-109

(4)

Camshaft one revolution (engine two revolutions)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the status where the number of camshaft position sensor signal in two engine revolutions is less than 3 time(s). Judgment Value Malfunction Criteria Amount of camshaft sensor signal during 2 revs.

Threshold Value < 3 time(s)

Time Needed for Diagnosis: 2 engine revs. × 50 Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria Camshaft position sensor signal

Threshold Value ≥ 3 time(s)

Time Needed for Diagnosis: Two engine revolutions

CC:DTC P0390 CAMSHAFT POSITION SENSOR “B” CIRCUIT (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0365.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CD:DTC P0400 EXHAUST GAS RECIRCULATION FLOW 1. OUTLINE OF DIAGNOSIS Detect EGR system malfunction. Intake manifold pressure (negative pressure) is constant because the throttle valve is fully closed during deceleration fuel cut. At this time, when the EGR valve is opened/closed, the intake manifold pressure will change. EGR System OK/NG is judged by the range of this change.

2. COMPONENT DESCRIPTION (7)

(1) (6)

(5)

(2) (4) (3)

EN-02192

(1) (2) (3)

ECM Detecting circuit Switching circuit

(4) (5)

CPU EGR valve

GD(H6DO)-111

(6) (7)

Main relay Battery power supply

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Elapsed time after starting the engine Engine coolant temperature Engine speed Intake manifold pressure (absolute pressure) Ambient air temperature Throttle position Battery voltage Atmospheric pressure Vehicle speed Fuel shut-off function Neutral switch After neutral switch ON/OFF change No load change (A/C, power steering, lighting, rear defogger, heater fan and radiator fan)

Enable Conditions ≥ 40 s ≥ 75 °C(167 °F) 1200 rpm — 3250 rpm < 46.7 kPa (350 mmHg, 13.8 inHg) ≥ 5 °C(41 °F) < 0.25 ° ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥53 km/h (32.9 MPH) In operation OFF ≥ Value from Map ≥ 5000 ms

Map Engine coolant temperature °C (°F) After neutral switch change msec

–40 (–40)

–30 (–22)

–20 (–4)

–10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

0

0

0

0

0

0

0

0

Engine coolant temperature °C (°F) After neutral switch change msec

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100 (212)

110 (230)

0

0

0

0

0

0

0

0

4. GENERAL DRIVING CYCLE During deceleration fuel cut from 53 km/h (approx. 33 MPH) or more, perform diagnosis once. Be careful of vehicle speed and engine speed. (Diagnosis will not be completed if the vehicle speed and engine speed conditions become out of specification due to deceleration.)

5. DIAGNOSTIC METHOD Measure the pressure values when the enable conditions are established, and perform diagnosis by calculating those results. 1. Label the intake manifold pressure value as PMOF1, which is observed when enable conditions are established, and set the EGR target step to 50 steps (nearly full open). 2. Name the intake manifold pressure value as PMON one second after the target EGR step is set to 50 (when the enabled conditions were established). Then set the target EGR step to 0. 3. Name the intake manifold pressure value as PMOF2 one second after the target EGR step is set to 0 (two seconds after the enabled conditions were established). • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria PMON – (PMOF1 + PMOF2)/2

Threshold Value < 1.6 kPa (11.8 mmHg, 0.5 inHg)

Time Needed for Diagnosis: 1 time Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION Start dignosis

(A)

Deceleration fuel cut

(B)

(C)

ON OFF

Diagnosis enable condition

(Open)

(D)

EGR target step (Close)

(Open) EGR actual step (Close)

PMON Intake manifold pressure (During normal condition)

PMOF2 PMOF1

DIagnostic mode timer

EN-05568

(A) (D)

2000 ms 50 step(s)

(B)

1500 ms

(C)

• Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria PMON – (PMOF1 + PMOF2)/2

Threshold Value ≥ 1.6 kPa (11.8 mmHg, 0.5 inHg)

Time Needed for Diagnosis: 1 time

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1500 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CE:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the deterioration of the catalyst function. Though the front oxygen sensor output would change slowly with a new catalyst, the sensor output with a deteriorated catalyst becomes high and the inversion time is shortened. For this reason, the catalyst diagnosis is carried out by monitoring the front oxygen sensor output and comparing it with the front oxygen (A/F) sensor output.

2. COMPONENT DESCRIPTION

(1)

(2)

(A)

(3)

(B)

(3)

(C)

(D)

EN-01713

(A)

Normal

(D)

Output waveform from the front oxygen sensor

(1)

Front oxygen (A/F) sensor

(B)

Deterioration

(C)

Output waveform from the front oxygen (A/F) sensor

(2)

Front oxygen sensor

(3)

Catalytic converter

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Battery voltage Atmospheric pressure Engine coolant temperature Estimated catalyst temperature Misfire detection every 200 rotations Learning value of evaporation gas density Sub feedback Evaporative system diagnosis Time of difference (< 0.10) between actual lambda and target lambda Vehicle speed Amount of intake air

Enable Conditions ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 75 °C (167 °F) ≥ 540 °C (1004 °F) < 7 time(s) < 0.2 In operation Not in operation ≥ 1000 ms

Engine load change every 0.5 engine revs. Rear oxygen output change from 660 mV or less to 660 mV or more Elapsed time after starting the engine Purge execution calculated time

> 60 km/h (37.3 MPH) ≥ 10 g/s (0.35 oz/s) and < 50 g/s (1.76 oz/s) < 0.02 g/rev (0 oz/rev) Experienced after fuel cut ≥ 220 s ≥5s

4. GENERAL DRIVING CYCLE Perform the diagnosis only once at a constant 60 km/h (37.3 MPH) or higher.

5. DIAGNOSTIC METHOD After the enable conditions have been established, calculate the front oxygen (A/F) sensor lambda value deviation cumulative value (Σ |(sglmdn – sglmdn–1 )|), and rear oxygen sensor output voltage deviation cumulative value (Σ |(ro2sadn – ro2sadn–1)|) in every 32 × 4 times. If the front oxygen (A/F) sensor lambda value deviation cumulative value (Σ |(sglmdn – sglmdn–1 )|) is the predetermined value or more, calculate the judgment value. • Abnormality Judgment If the duration of time while the following conditions are met is within the time indicated, judge as NG. Judgment Value Malfunction Criteria Σ |(ro2sadn – ro2sadn–1)| / Σ |(sglmdn – sglmdn–1)|

Threshold Value > 18 (Bin5 model) > 16 (ULEV model)

Time Needed for Diagnosis: 30 — 55 seconds Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is within the predetermined time. Judgment Value Malfunction Criteria Σ |(ro2sadn – ro2sadn–1)| / Σ |(sglmdn – sglmdn–1)|

Threshold Value ≤ 18 (Bin5 model) ≤ 16 (ULEV model)

Time Needed for Diagnosis: 30 — 55 seconds

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CF:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK) 1. OUTLINE OF DIAGNOSIS Check if there is a leakage in fuel system or not, and perform the function diagnosis of valve.

(4) (1)

(2)

(3)

(5)

(14)

(13) (15) (8) (7) (9)

(12)

(11)

(10)

(6)

EN-07995

(1) (2) (3) (4) (5)

Fuel gauge Intake manifold Throttle body Purge control solenoid valve Engine control module (ECM)

(6) (7) (8) (9) (10)

Canister Drain valve Drain filter Shut-off valve Fuel temperature sensor

(11) (12) (13) (14) (15)

Fuel level sensor Fuel tank Fuel cut valve Fuel tank pressure sensor Vent valve

In this system diagnosis, check for leakage and valve function is conducted by changing the fuel tank pressure and monitoring the pressure change using the fuel tank pressure sensor. When in 0.04 inch diagnosis, perform in the order of mode Z → mode A → mode B → mode C and mode D; When in 0.02 inch diagnosis, perform in the order of mode A → mode B → mode C → mode D and mode E.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

0.04-inch Diagnosis

Mode Z

OK

Mode A

OK

Mode B

OK

Mode C

OK

Mode D

OK

NG Early OK Large leakage judgement

END

Cancel

NG

Mode Z Extend

NG OK

EN-02872

Mode Mode Z (Purge control solenoid valve opening failure diagnosis) Mode A (Estimated evaporation amount) Mode B (Sealed negative pressure, large leakage judgment) Mode C (Pressure increase check, advanced OK judgment)

Mode Description

Diagnosis Period

Perform purge control solenoid valve opening failure diagnosis from the size of tank pressure variation from diagnosis start.

5000 ms + 3000 ms — 5000 ms + 3000 ms + 13000 ms

Calculate the tank pressure change amount (P1).

10000 ms

Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank. If the tank pressure cannot be reduced, it is diagnosed as large leak.

0 — 10000 ms + 25000 ms

Wait until the tank pressure returns to the target (start level of P2 calculation). If the tank pressure does not become the value, make advanced OK judgment.

0 — 14013 ms

Mode D Calculate the tank pressure variation (P2), and obtain the diagnostic (Negative pressure variation value using P1 found in Mode A. measurement, evaporation leakPerform the evaporation diagnosis using the diagnostic value. age diagnosis)

0 ms + 10000 ms

Mode Table for Evaporative Emission Control System Diagnosis Mode Mode Z Mode A Mode B Mode C Mode D

Behavior of tank internal pressure under normal conditions Diagnostic item Roughly the same as barometric pressure (Same as 0 kPa Purge control solenoid valve is judged (0 mmHg, 0 inHg)) to be open. Pressure is in proportion to amount of evaporative emission. Negative pressure is formed due to intake manifold negative pressure Reaches target pressure Pressure change is small.

— Large leak

P0457 None P0457

— EVAP system large leak determination. [1.0 mm (0.04 in)]

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DTC

None P0442

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

0.02-inch Diagnosis

Mode A

OK

Mode B

OK

Mode C

OK

OK

Mode D

Mode E

Cancel Early OK 2 Cancel

END

Early OK 1 Cancel Cancel Cancel

EN-02871

Mode Mode A (0 point compensation)

Mode Description When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg).

Diagnosis Period 0 — Value of Map 1

Mode B (Negative pressure introduced)

Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank.

Mode C (Negative pressure maintained) Mode D (Negative pressure change calculated)

Wait until the tank pressure returns to the target (start level of P2 calculation).

Value from Map 3

Calculate the time it takes for the tank pressure to change to the Mode E shifting pressure. If the tank pressure does not change to the Mode E shifting pressure, make advanced OK judgment.

0 — 0 ms + Value from Map 4

Mode E (Evaporation generated amount calculation)

Calculate the amount of evaporation (P1).

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0 — Value of Map 2

0 — 0 ms + Value from Map 4 + Value from Map 5

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Map 1 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

10, 2.64, 2.2 6400

20, 5.28, 4.4 6530

10.5

27, 7.13, 5.94

43, 11.36, 9.46

20280

20621

21816

10.5

27, 7.13, 5.94

43, 11.36, 9.46

21208

19288

9742

59.5, 15.72, 13.09 8057

20, 5.28, 4.4 200000

30, 7.93, 6.6 200000

20, 5.28, 4.4 70000

30, 7.93, 6.6 60000

0 6400

30, 7.93, 6.6 6660

40, 10.57, 8.8 7020

50, 13.21, 11 7380

40, 10.57, 8.8 200000

50, 13.21, 11 200000

60, 15.85, 13.2 200000

40, 10.57, 8.8 60000

50, 13.21, 11 60000

60, 15.85, 13.2 60000

60, 15.85, 13.2 7380

Map 2 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

59.5, 15.72, 13.09 21816

Map 3 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

Map4 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

10 200000

Map 5 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

10 80000

2. COMPONENT DESCRIPTION Drain valve controls the ambient air to be introduced to the canister.

EN-02293

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION 0.04-inch Diagnosis Secondary Parameters Battery voltage Atmospheric pressure Total time of canister purge operation Learning value of evaporation gas density Engine speed Fuel tank pressure Intake manifold relative vacuum (relative pressure) Continuous time of the status where fuel level is 10.5 2 (2.77 US gal, 2.31 Imp gal) — 59.5 2 (15.72 US gal, 13.09 Imp gal) Closed air/fuel ratio control Fuel temperature Intake air temperature Pressure variation every one second Minimum pressure variation value every one second – Maximum pressure variation value every one second Fuel level variation every 128 ms Air fuel ratio Elapsed time after starting the engine or Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 120000 ms < 0.08 1050 rpm — 4000 rpm ≥ –4 kPa (–30 mmHg, –1.2 inHg) ≥ –13.3 kPa (–100 mmHg, –3.9 inHg) ≥ 37000 ms

In operation –10 °C (14 °F) — 45 °C (113 °F) ≥ –10 °C (14 °F) < 1.7 mmHg (Mode A) < 1.7 mmHg (Mode D) < 1.7 mmHg (Mode A) < 1.7 mmHg (Mode D) < Value of Map 6 0.76 — 1.25 ≥ 851 s ≥ 335 s and Vehicle speed 72 km/h (44.7 MPH) or more

Map 6 Fuel level (2, US gal, Imp gal)

10, 2.64, 2.2

20, 5.28, 4.4

25, 6.61, 5.5

30, 7.93, 6.6

43, 11.36, 9.46

45, 11.89, 9.9

50, 13.21, 11

60, 15.85, 13.2

Change (2, US gal, Imp gal)

4, 1.06, 0.88

5, 1.32, 1.1

6.5, 1.72, 1.43

4, 1.06, 0.88

5, 1.32, 1.1

5, 1.32, 1.1

6, 1.59, 1.32

8, 2.11, 1.76

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

0.02-inch Diagnosis Secondary Parameters At starting a diagnosis Evap. diagnosis Battery voltage Atmospheric pressure Time since last incomplete 0.02-inch leakage diagnosis When cancelling in mode A When cancelling in other than mode A Total time of canister purge operation Elapsed time after starting the engine Fuel temperature Continuous time of the status where fuel level is 10.5 2 (2.77 US gal, 2.31 Imp gal) — 59.5 2 (15.72 US gal, 13.09 Imp gal) Intake manifold relative vacuum (relative pressure) Fuel tank pressure Closed air/fuel ratio control Engine speed Vehicle speed During diagnosis Change of fuel level Pressure variation every one second Minimum pressure variation value every one second – Maximum pressure variation value every one second |Tank pressure variation every one second| Barometric pressure change

Enable Conditions Incomplete ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg)

> 120000 ms > 240000 ms ≥ 120000 ms ≥ 120 s –10 °C (14 °F) — 55 °C (131 °F) ≥ 37000 ms

≥ –8 kPa (–60 mmHg, –2.4 inHg) –0.7 kPa (–5 mmHg, –0.2 inHg) — 0.4 kPa (2.9 mmHg, 0.1 inHg) In operation 1050 rpm — 4000 rpm Continue the status of 50 km/h (31.1 MPH) — 510 km/h (316.9 MPH) for 125000 ms or more. ≤ Value of Map 7 < 0.1 kPa (0.44 mmHg, 0 inHg) < 0.1 kPa (0.51 mmHg, 0 inHg) (Mode D)

≤ 0.1 kPa (0.75 mmHg, 0 inHg) –0.5 kPa (–3.6 mmHg, –0.1 inHg) — 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode D) –0.3 kPa (–2.4 mmHg, –0.1 inHg) — 0.3 kPa (2.4 mmHg, 0.1 inHg) (Mode E)

Map 7 Fuel level (2, US gal, Imp gal)

10, 2.64, 2.2

20, 5.28, 4.4

25, 6.61, 5.5

30, 7.93, 6.6

43, 11.36, 9.46

45, 11.89, 9.9

50, 13.21, 11

60, 15.85, 13.2

Change (2, US gal, Imp gal)

4, 1.06, 0.88

5, 1.32, 1.1

6.5, 1.72, 1.43

4, 1.06, 0.88

5, 1.32, 1.1

5, 1.32, 1.1

6, 1.59, 1.32

8, 2.11, 1.76

4. GENERAL DRIVING CYCLE 0.04-inch Diagnosis • Perform the diagnosis only once, 335 seconds or more after starting the engine, at a constant speed of 72 km/h (45 MPH) or more. • Pay attention to the fuel temperature and fuel level. 0.02-inch Diagnosis • Perform the diagnosis after 125 seconds or more have elapsed at a constant engine speed of 50 km/h (31 MPH) or higher to judge as NG or OK. • If judgment cannot be made, repeat the diagnosis. • Pay attention to the fuel level.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD Purge control solenoid valve stuck open fault diagnosis DTC P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) Purpose of Mode Z When performing the leakage diagnosis of EVAP system, the purge control solenoid valve must operate normally. Therefore, mode Z is used to diagnose the purge control solenoid valve stuck open condition. Note that if a purge control solenoid valve stuck open fault is detected, the EVAP system leakage diagnosis is cancelled. Diagnostic method Purge control solenoid valve functional diagnosis is performed by monitoring the tank pressure in mode Z. • Abnormality Judgment If OK judgment cannot be made, extend Mode Z, and Judge as NG when the following conditions are established after predetermined amount of time. Judgment Value Malfunction Criteria evptez – evptezha evptezini Time of no fuel sloshing with value from Map 6 or more

Threshold Value > 0.9 kPa (6.5 mmHg, 0.3 inHg) ≤ 0.4 kPa (2.9 mmHg, 0.1 inHg) ≥ 40000 ms

DTC P0457

Time Needed for Diagnosis: 5000 ms + 3000 ms + 13000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. When judgment for purge control solenoid valve stuck open NG is made, end the evaporative diagnosis. Cancel the evaporative diagnosis when the OK/NG judgment for purge control solenoid valve stuck open cannot be made in Mode Z. • Normality Judgment Judge as OK and change to Mode A when the following conditions are established after 3000 ms has passed since Mode Z started. Judgment Value Malfunction Criteria evptez – evptezha

Threshold Value ≤ 0.4 kPa (3 mmHg, 0.1 inHg)

DTC P0457

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Normal (1)

(2) evptez evptezha

evptezini

(3) 0

(4)

(5) EN-02869

(1) (2)

Mode Z 3000 ms

(3) (4)

Fuel tank pressure 0.4 kPa (3 mmHg, 0.1 inHg)

(5)

OK judgment

evptez – evptezha ≤ 0.4 kPa (3 mmHg, 0.1 inHg) Normal when above is established Time Needed for Diagnosis: 5000 ms + 3000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Purge control solenoid valve Open Fixation

(1)

(2) (3)

(6) evptez evptezini

(4) 0

(5)

evptezha

(7)

(8)

EN-02870

(1) (2) (3)

Mode Z Extended mode Z 5000 ms + 3000 ms + 13000 ms

(4) (5) (6)

Fuel tank pressure 0.9 kPa (6.5 mmHg, 0.3 inHg) 0.4 kPa (2.9 mmHg, 0.1 inHg)

• evptezini ≤ 0.4 kPa (2.9 mmHg, 0.1 inHg) • evptez – evptezha > 0.9 kPa (6.5 mmHg, 0.3 inHg) • No fuel sloshing with value from Map 6 or more lasts for 40000 ms. Judge as abnormal when all are established.

GD(H6DO)-124

(7) (8)

40000 ms no fuel sloshing NG judgment

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Leak Diagnosis DTC P0442 Evaporative Emission Control System Leak Detected (Small Leak) P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off) • The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. • The diagnosis is divided into the following five phases. Mode A: (Estimated evaporation gas amount) Calculate the tank pressure change amount (P1) when using mode A. After calculating P1, switch to mode B. Mode B: (Negative pressure sealed) Introduce negative pressure in the intake manifold to the tank. Approx. 0 → –1.4 kPa (0 → –10.5 mmHg, 0 → –0.4 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. In this case, if the tank pressure does not reach the target negative pressure, judge that there is a large leakage in the system and terminate the evaporative emission control system diagnosis. Abnormality Judgment Judge as NG (large leakage) when the following conditions are established. Judgment Value Malfunction Criteria Time to reach target negative pressure or Mode B time (Min. pressure value in tank when in mode B) – (Tank pressure when mode B started)

Threshold Value DTC ≥ 10000 ms + 25000 ms P0457 ≥ 10000 ms > –0.5 kPa (–4 mmHg, –0.2 inHg)

Time Needed for Diagnosis: 5000 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms Mode C: (Check pressure rise) Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.) Change to Mode D when the tank pressure returns to the start level of P2 calculation. Judge immediate OK and change to Mode E when it does not return in spite of spending the specified time. Tank pressure when starting calculation of P2 –1.3 kPa (–9.75 mmHg, –0.4 inHg)

Time for advanced OK judgment 14013 ms

Time Needed for Diagnosis: 5000 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 14013 ms Mode D: (Measure amount of negative pressure change) Monitor the tank pressure change amount when using mode D. In this case, the tank pressure increases, (nears barometric pressure) because evaporation occurs. However, if any leakage exists, the pressure increases additionally in proportion to this leakage. The pressure variation of this tank is P2. After calculating P2, perform a small leak diagnosis according to the items below. When Mode D is ended Assign tank variations measured in Mode A and Mode D, P1 and P2, to the formula below, judge small leaks in the system. If the measured judgment value exceeds the threshold value, it is judged to be a malfunction.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Abnormality Judgment Judge as NG when the following conditions are established within the predetermined time. Judge as OK and clear the NG if the following conditions are not established within the predetermined time. Judgment Value Malfunction Criteria P2 – 1.5 – × P1 P2: Tank pressure that changes every 10000 ms in mode D P1: Tank pressure that changes every 10000 ms in mode A

Threshold Value > Value of Map 8

DTC P0442

*1.5 –: Evaporation amount compensation value when below negative pressure (Amount of evaporation occurrence increases as a vacuum condition increases.)

Map 8 Fault criteria limit for Evaporative emission control system diagnosis Fuel temperature vs. Fuel level 10.5 2 (2.77 US gal, 2.31 Imp gal) 27 2 (7.13 US gal, 5.94 Imp gal) 43 2 (11.36 US gal, 9.46 Imp gal) 59.5 2 (15.72 US gal, 13.09 Imp gal)

15 °C (59 °F) 0.3 kPa (2.1 mmHg, 0.1 inHg) 0.3 kPa (2.32 mmHg, 0.1 inHg) 0.4 kPa (2.88 mmHg, 0.1 inHg) 0.5 kPa (3.5 mmHg, 0.1 inHg)

25 °C (77 °F) 0.3 kPa (2.1 mmHg, 0.1 inHg) 0.3 kPa (2.5 mmHg, 0.1 inHg) 0.4 kPa (2.97 mmHg, 0.1 inHg) 0.5 kPa (3.5 mmHg, 0.1 inHg)

35 °C (95 °F) 0.3 kPa (2.3 mmHg, 0.1 inHg) 0.4 kPa (2.73 mmHg, 0.1 inHg) 0.4 kPa (3.23 mmHg, 0.1 inHg) 0.5 kPa (3.5 mmHg, 0.1 inHg)

45 °C (113 °F) 0.3 kPa (2.4 mmHg, 0.1 inHg) 0.4 kPa (2.88 mmHg, 0.1 inHg) 0.5 kPa (3.43 mmHg, 0.1 inHg) 0.5 kPa (3.7 mmHg, 0.1 inHg)

Time Needed for Diagnosis: 5000 ms + 3000 ms + 10000 ms + 10000 ms + 25000 ms + 14013 ms + 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Leak Diagnosis DTC P0456 Evaporative Emission Control System Leak Detected (very small leak) • The diagnostic consists of creating a sealed vacuum in the fuel tank and then determining the presence of leakage from the speed at which the tank internal pressure returns to barometric pressure. • The diagnosis is divided into the following five phases. Mode A: (0 point compensation) When the pressure in the tank is not near 0 mmHg, wait until it returns to 0 point (near 0 mmHg). Shift to mode B when returned to the 0 point. Cancel the diagnosis when 0 point does not return in the specified time. Mode B: (Negative pressure introduced) Introduce negative pressure in the intake manifold to the tank. Approx. 0 → –2 kPa (0 → –15 mmHg, 0 → –0.6 inHg) When the pressure above (desired negative pressure) is reached, enters Mode C. When the tank internal pressure does not reach the target vacuum pressure, the diagnosis is cancelled. Mode C: (Negative pressure maintained) Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.) Change to Mode D either when the tank pressure returns to the start level of P2 calculation, or when the predetermined amount of time has passed. Mode D: (Calculate the amount of negative pressure change) Monitor the tank pressure in mode D, calculate (P2) the pressure change in the tank, and measure the time (evpdset) for the tank pressure to change to the Mode E shifting pressure. When the Mode E shifting pressure is reached, Mode E is entered. If it does not change to the Mode E shifting pressure after the predetermined amount of time has passed, make advanced OK judgment or cancel the diagnosis.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

Normality Judgment Judge as OK when the following conditions are established. Judgment Value Malfunction Criteria Advanced OK judgment 1 Mode D time Tank internal pressure Advanced OK judgment 2 Mode D time P2

Threshold Value ≥ 0 ms + 20000 ms ≤ Value of Map 9 ≥ 0 ms + Value of Map 10 ≤ Value of Map 11

Map 9 Fuel level (2, US gal, Imp gal) Tank pressure (kPa, mmHg, inHgl)

10.5, 2.77, 2.31

27, 7.13, 5.94

–1.9, –14.61, –0.6

–1.9, –14.61, –0.6

43, 11.36, 9.46 –1.8, –13.64, –0.5

59.5, 15.72, 13.09 –1.8, –13.13, –0.5

10, 2.64, 2.2

20, 5.28, 4.4

30, 7.93, 6.6

40, 10.57, 8.8

50, 13.21, 11

200000

200000

200000

200000

200000

10.5, 2.77, 2.31

27, 7.13, 5.94

43, 11.36, 9.46

59.5, 15.72, 13.09

1.1, 8.52, 0.3

1.1, 8.52, 0.3

1.3, 10, 0.4

1.3, 10, 0.4

Map 10 Fuel level (2, US gal, Imp gal) Time Needed for Diagnosis (ms)

60, 15.85, 13.2 200000

Map 11 Fuel level (2, US gal, Imp gal) Tank pressure (kPa, mmHg, inHgl)

Mode E: (Evaporation occurrence amount calculation) Calculate the change of tank pressure with the time evpdset (P1) to judge as NG/OK according to the value of P1. (ambiguous determination acceptable).

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria P1

Threshold Value < Value of Map 12

Map 12 Malfunction criteria limit for evaporation diagnosis Time (evpdset) vs Fuel level 10.5 2 (2.77 US gal, 2.31 Imp gal) 27 2 (7.13 US gal, 5.94 Imp gal) 43 2 (11.36 US gal, 9.46 Imp gal) 59.5 2 (15.72 US gal, 13.09 Imp gal)

40000 ms

60000 ms

105000 ms

110000 ms

140000 ms

160000 ms

180000 ms

200000 ms

0 kPa 0.1 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.4 kPa 0.4 kPa 0.4 kPa (0.00 mmHg, (0.70 mmHg, (2.18 mmHg, (2.23 mmHg, (2.53 mmHg, (2.72 mmHg, (2.90 mmHg, (2.90 mmHg, 0 inHg) 0 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.4 kPa 0.4 kPa 0.4 kPa 0.4 kPa 0 kPa 0.2 kPa 0.3 kPa 0.3 kPa (0.00 mmHg, (1.81 mmHg, (2.46 mmHg, (2.53 mmHg, (2.90 mmHg, (2.90 mmHg, (2.90 mmHg, (2.90 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0 inHg) 0 kPa 0.2 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0.3 kPa 0 kPa (0.00 (0.00 mmHg, (1.53 mmHg, (2.49 mmHg, (2.60 mmHg, (2.60 mmHg, (2.60 mmHg, (2.60 mmHg, mmHg, 0 0 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) inHg) 0.3 kPa 0.3 kPa 0.3 kPa 0.2 kPa 0 kPa 0 kPa 0.2 kPa 0.3 kPa (0.00 mmHg, (1.31 mmHg, (2.53 mmHg, (2.53 mmHg, (2.53 mmHg, (2.53 mmHg, (1.26 mmHg, (0.00 mmHg, 0.1 inHg) 0.1 inHg) 0.1 inHg) 0 inHg) 0 inHg) 0 inHg) 0.1 inHg) 0.1 inHg)

Time needed for diagnosis: Value from Map 1 + Value from Map 2 + Value from Map 3 + 0 ms + Value from Map 4 + 0 ms + Value from Map 4 + Value from Map 5 Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK when the following conditions are established. Judgment Value Malfunction Criteria P1

Threshold Value > Value of Map 13

Map 13 Malfunction criteria limit for evaporation diagnosis Time (evpdset) vs Fuel level 10.5 2 (2.77 US gal, 2.31 Imp gal) 27 2 (7.13 US gal, 5.94 Imp gal) 43 2 (11.36 US gal, 9.46 Imp gal) 59.5 2 (15.72 US gal, 13.09 Imp gal)

20000 ms

60000 ms

105000 ms

110000 ms

140000 ms

160000 ms

180000 ms

200000 ms

0 kPa 0.3 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.6 kPa 0.6 kPa 0.6 kPa (0.00 mmHg, (2.20 mmHg, (3.68 mmHg, (3.73 mmHg, (4.03 mmHg, (4.22 mmHg, (4.40 mmHg, (4.40 mmHg, 0 inHg) 0.1 inHg) 0.1 inHg) 0.1 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0 kPa 0.4 kPa 0.5 kPa 0.5 kPa 0.6 kPa 0.6 kPa 0.6 kPa 0.6 kPa (0.00 mmHg, (3.31 mmHg, (3.96 mmHg, (4.03 mmHg, (4.40 mmHg, (4.40 mmHg, (4.40 mmHg, (4.40 mmHg, 0 inHg) 0.1 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0 kPa 0.4 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa 0.2 kPa (0.00 mmHg, (3.03 mmHg, (3.99 mmHg, (4.10 mmHg, (4.10 mmHg, (4.10 mmHg, (4.10 mmHg, (1.50 mmHg, 0 inHg) 0.1 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.1 inHg) 0.5 kPa 0.5 kPa 0.5 kPa 0.4 kPa 0.2 kPa 0 kPa 0.4 kPa 0.5 kPa (0.00 mmHg, (2.81 mmHg, (4.03 mmHg, (4.03 mmHg, (4.03 mmHg, (4.03 mmHg, (2.76 mmHg, (1.50 mmHg, 0.2 inHg) 0.2 inHg) 0.2 inHg) 0.1 inHg) 0.1 inHg) 0 inHg) 0.1 inHg) 0.2 inHg)

Time needed for diagnosis: Value from Map 1 + Value from Map 2 + Value from Map 3 + 0 ms + Value from Map 4 + 0 ms + Value from Map 4 + Value from Map 5

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CG:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the drain valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (19)

(14)

(9)

(10)

(15)

(11)

(16)

(12)

(8)

(13)

(7)

(17)

(4)

(2)

(5)

(19)

(6)

(1)

(18)

(3) EN-02294

(1) (2) (3) (4) (5) (6) (7)

Bobbin Coil Diode Stator core End plate Body Yoke

(8) (9) (10) (11) (12) (13) (14)

Magnetic plate Shaft Plate Valve Housing Filter Retainer

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(15) (16) (17) (18) (19)

Diaphragm Movable core Spring Cover O-ring

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal

Threshold Value ≥ 10.9 V ≥1s Low

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs OFF signal

Threshold Value ≥ 10.9 V ≥1s High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CH:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the drain valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (19)

(14)

(9)

(10)

(15)

(11)

(16)

(12)

(8)

(13)

(7)

(17)

(4)

(2)

(5)

(19)

(6)

(1)

(18)

(3) EN-02294

(1) (2) (3) (4) (5) (6) (7)

Bobbin Coil Diode Stator core End plate Body Yoke

(8) (9) (10) (11) (12) (13) (14)

Magnetic plate Shaft Plate Valve Housing Filter Retainer

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(15) (16) (17) (18) (19)

Diaphragm Movable core Spring Cover O-ring

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal

Threshold Value ≥ 10.9 V ≥1s High

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Terminal output voltage when ECM outputs ON signal

Threshold Value ≥ 10.9 V ≥1s Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CI: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR 1. OUTLINE OF DIAGNOSIS Detect the tank pressure sensor output property abnormality. Judge as NG when there is no pressure variation, which should exist in the tank, considering the engine status.

2. COMPONENT DESCRIPTION

(A) (1)

(2)

(B) (C)

EN-04462

(A)

Output voltage

(B)

Input voltage

(1)

Connector

(2)

Terminals

(C)

To fuel tank

3. ENABLE CONDITION Secondary Parameters Elapsed time after starting the engine Fuel level Fuel temperature Battery voltage Barometric pressure

Enable Conditions ≥ 60 s ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) < 35 °C (95 °F) ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg)

4. GENERAL DRIVING CYCLE • Perform the diagnosis continuously after 60 s have passed since the engine started. • Pay attention to the fuel level and temperature.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Number of times that the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is 2 2 (0.53 US gal, 0.44 Imp gal) or more (with enable condition established) Maximum – Minimum tank pressure (with enable condition completed) Maximum – Minimum fuel temperature (with enable condition completed)

Threshold Value ≥ 16 time(s)

< 0 kPa (0.375 mmHg, 0 inHg) ≥ 7 °C (44.6 °F)

If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is less than 2 2 (0.53 US gal, 0.44 Imp gal), extend 60 s and make judgment with the Max. and Min. values for the fuel level in 60 s × 2. 60 s If a difference does not appear, extend the time (60 s × 3, 60 s × 4, 60 s × 5) and continue the judgment. If the difference between the Max. fuel level every 60 s and Min. fuel level every 60 s is 2 2 (0.53 US gal, 0.44 Imp gal) or more, the diagnosis counter counts up. Time Needed for Diagnosis: 60 s × 16 time(s) or more Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Maximum — Minimum tank pressure

Threshold Value ≥ 0 kPa (0.375 mmHg, 0 inHg)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CJ:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the fuel tank pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A) (1)

(2)

(B) (C)

EN-04462

(A)

Output voltage

(B)

Input voltage

(1)

Connector

(2)

Terminals

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(C)

To fuel tank

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Fuel tank pressure Battery voltage

Threshold Value < –7.4 kPa (–55.6 mmHg, –2.2 inHg) ≥ 10.9 V

Time Needed for Diagnosis: 15000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Fuel tank pressure Battery voltage

Threshold Value ≥ –7.4 kPa (–55.6 mmHg, –2.2 inHg) ≥ 10.9 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CK:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of the fuel tank pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(A) (1)

(2)

(B) (C)

EN-04462

(A)

Output voltage

(B)

Input voltage

(1)

Connector

(2)

Terminals

(C)

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Vehicle speed All conditions of EVAP canister purge Learning value of evaporation gas concentration (left and right) Main feedback compensation coefficient (left and right) Battery voltage

Enable Conditions ≥ 5000 ms ≥ 2 km/h (1.2 MPH) Completed < 0.08 ≥ 0.9 ≥ 10.9 V

4. GENERAL DRIVING CYCLE Perform the diagnosis when purging enable conditions are met without idling.

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To fuel tank

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Fuel tank pressure Fuel temperature Atmospheric pressure

Threshold Value ≥ 7.9 kPa (59.6 mmHg, 2.3 inHg) < 35 °C (95 °F) ≥ 75 kPa (563 mmHg, 22.2 inHg)

Time Needed for Diagnosis: 15000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Fuel tank pressure

Threshold Value < 7.9 kPa (59.6 mmHg, 2.3 inHg)

Time Needed for Diagnosis: Less than 1 second

CL:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0442.

CM:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF) 1. OUTLINE OF DIAGNOSIS For the detection standard, refer to DTC P0442.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CN:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the purge control solenoid valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (B)

(A)

EN-02197

(A)

To canister

(B)

To intake manifold

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥1s

4. GENERAL DRIVING CYCLE Always perform the diagnosis after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Duty ratio of “ON” Terminal output voltage

Threshold Value < 0.75 Low

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal output voltage

Threshold Value High

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CO:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the purge control solenoid valve. Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (B)

(A)

EN-02197

(A)

To canister

(B)

To intake manifold

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥1s

4. GENERAL DRIVING CYCLE Always perform the diagnosis after starting the engine.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Duty ratio of “ON” Terminal output voltage

Threshold Value ≥ 0.25 High

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal output voltage

Threshold Value Low

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CP:DTC P0461 FUEL LEVEL SENSOR “A” CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect malfunctions of the fuel level sensor output property. If the fuel level does not vary in a particular driving condition / engine condition where it should, judge as NG.

2. COMPONENT DESCRIPTION

(A)

0

(B)

EN-01734

(A)

Fuel level

(B)

Resistance

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Accumulated amount of intake air Max. – min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine

Threshold Value ≥ 330957 g (11672.85 oz) < 2.6 2 (0.69 US gal, 0.57 Imp gal) ≥ 10.9 V < 4000 rpm ≥ 5000 ms

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Accumulated amount of intake air Max. – min. values of fuel level output Battery voltage Engine speed Elapsed time after starting the engine

Threshold Value ≥ 330957 g (11672.85 oz) ≥ 2.6 2 (0.69 US gal, 0.57 Imp gal) ≥ 10.9 V < 4000 rpm ≥ 5000 ms

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CQ:DTC P0462 FUEL LEVEL SENSOR “A” CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel level sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(5)

(1)

(4)

(2)

(3)

EN-05371

(1) (2)

Engine control module (ECM) Fuel level sensor

(3) (5)

Fuel sub level sensor Body integrated unit

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Detecting circuit

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms < 0.173 V

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms ≥ 0.173 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CR:DTC P0463 FUEL LEVEL SENSOR “A” CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of fuel level sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION

(5)

(1)

(4)

(2)

(3)

EN-05371

(1) (2)

Engine control module (ECM) Fuel level sensor

(3) (5)

Fuel sub level sensor Body integrated unit

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Detecting circuit

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms ≥ 7.212 V

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Elapsed time after starting the engine Output voltage

Threshold Value ≥ 10.9 V ≥ 3000 ms < 7.212 V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CS:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT 1. OUTLINE OF DIAGNOSIS Detect the unstable output faults from the fuel level sensor caused by noise. Judge as NG when the max. value and cumulative value of output voltage variation of the fuel level sensor is larger than the threshold value.

2. ENABLE CONDITION Malfunction Criteria Engine speed Elapsed time after starting the engine Battery voltage Idle switch Fuel level

Vehicle speed = 0 km/h (0 MPH)

Threshold Value ≥ 500 rpm ≥1s ≥ 10.9 V ON ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) and < 59.5 2 (15.72 US gal, 13.09 Imp gal) ≥ 10000 ms

3. GENERAL DRIVING CYCLE • Always perform the diagnosis continuously at idle speed. • Pay attention to the fuel level.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

4. DIAGNOSTIC METHOD Calculate the Max. value (DELFLMAX) and cumulative value (SUMFL) of output voltage variation of fuel level sensor during 12.2 seconds. Judge it normal when both max. and cumulative values are not over the threshold value. Otherwise, when either of them is over the threshold value, the diagnosis counter counts up. Judge as NG if the counter indicated 4 time(s).

Diagnosis condition

(A) Diagnosis timer

Fuel level sensor A/D value

(C) (D)

Amount of Fuel level output voltage variation

Calculate the Max. value (DELFLMAX) and the cumulative value (SUMFL).

5

6

4 3 2 1 Diagnosis counter

0

(B) EN-05569

(A) (D)

12288 ms Normal

(B)

NG at 4 time(s) counts

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(C)

Malfunction

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

• Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Integrated times of the condition reaching follows, DELFLMAX or SUMFL At this time, DELFLMAX: Maximum difference of sensor output for 12288 ms SUMFL: Integrated value of the sensor output deviation for12288 ms

Threshold Value ≥ 4 time(s) ≥ Value from Map ≥ 23.8 V

Map Fuel level (2, US gal, Imp gal) Measured voltage (V)

10, 2.64, 2.2 0.248

20, 5.28, 4.4 0.519

25, 6.61, 5.5 0.796

30, 7.93, 6.6 0.6

43, 11.36, 9.46 1.025

45, 11.89, 9.9 1.069

50, 13.21, 11 1.402

The diagnosis counter does not count up when the following conditions are completed within 12288 ms. Maximum value – minimum value of change of tank pressure during 12288 ms Maximum value – minimum value of battery voltage during 12288 ms

≥ 0 kPa (0.375031 mmHg, 0 inHg) ≥ 1.2 V

Time Needed for Diagnosis: 12288 ms × 4 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Threshold Value DELFLMAX < Value from Map SUMFL < 23.8 V At this time, DELFLMAX: Maximum difference of sensor output for 12288 ms SUMFL: Integrated value of the sensor output deviation for12288 ms

Time Needed for Diagnosis: 12288 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CT:DTC P0500 VEHICLE SPEED SENSOR “A” 1. OUTLINE OF DIAGNOSIS Judge as NG when outside of the judgment value. Judge NG when the received data from VDCCM&H/U is abnormal vehicle speed, and the vehicle speed data is impossible.

2. COMPONENT DESCRIPTION Vehicle speed signals are taken in to the VDC control module and hydraulic control unit, and normal/erroneous data of the ABS wheel speed sensor is received by CAN communication from the VDC control module and hydraulic control unit.

3. ENABLE CONDITION Secondary Parameters Battery voltage Elapsed time after starting the engine

Enable Conditions ≥ 10.9 V ≥ 2000 ms

4. GENERAL DRIVING CYCLE Always perform diagnosis more than 2000 ms after starting the engine.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Front ABS wheel speed sensor status Either of the following is established Front left wheel speed Front right wheel speed

Threshold Value Malfunction ≥ 300 km/h (186.4 MPH) ≥ 300 km/h (186.4 MPH)

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Front left wheel speed

Front right wheel speed

Threshold Value > 0 km/h (0 MPH) and < 300 km/h (186.4 MPH) > 0 km/h (0 MPH) and < 300 km/h (186.4 MPH)

Time Needed for Diagnosis: 2500 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CU:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED 1. OUTLINE OF DIAGNOSIS Detect the malfunction that actual engine speed is not close to target engine speed during idling. Judge as NG when actual engine speed is not close to target engine speed during idling.

2. ENABLE CONDITION Secondary Parameters Engine coolant temperature Battery voltage Atmospheric pressure Fuel level Elapsed time after starting the engine Feedback of ISC Lambda value (left and right)

After switching air conditioner to ON/ OFF After intake manifold pressure changes by 4 kPa (30 mmHg, 1.2 inHg) or more. Elapsed time after switching neutral position switch to ON/OFF Vehicle speed

Enable Conditions ≥ 75 °C (167 °F) ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) ≥ 10.49 s In operation ≥ 0.9 and < 1.1 ≥ 5.1 s > 5.1 s > 5.1 s 0 km/h (0 MPH)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling after warming up engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Actual engine speed — Targeted engine speed Feedback compensation for ISC

Threshold Value < –100 rpm Max.

Time Needed for Diagnosis: 10 s × 3 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Actual engine speed — Targeted engine speed

Threshold Value ≥ –100 rpm

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CV:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED 1. OUTLINE OF DIAGNOSIS Detect the malfunction that actual engine speed is not close to target engine speed during idling. Judge as NG when actual engine speed is not close to target engine speed during idling.

2. ENABLE CONDITION Secondary Parameters Engine coolant temperature Battery voltage Atmospheric pressure Fuel level Elapsed time after starting the engine Feedback of ISC Lambda value (left and right)

After switching air conditioner to ON/ OFF After intake manifold pressure changes by 4 kPa (30 mmHg, 1.2 inHg) or more. Elapsed time after switching neutral position switch to ON/OFF Vehicle speed

Enable Conditions ≥ 75 °C (167 °F) ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 10.5 2 (2.77 US gal, 2.31 Imp gal) ≥ 10.49 s In operation ≥ 0.9 and < 1.1 ≥ 5.1 s > 5.1 s > 5.1 s 0 km/h (0 MPH)

3. GENERAL DRIVING CYCLE Perform the diagnosis continuously at idling after warming up engine.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Actual – Target engine speed Feedback value for ISC

Threshold Value ≥ 200 rpm Min.

Time Needed for Diagnosis: 10 s × 3 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Actual – Target engine speed

Threshold Value < 200 rpm

Time Needed for Diagnosis: 10 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CW:DTC P0512 STARTER REQUEST CIRCUIT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of starter SW. Judge as ON NG when the starter SW signal remains ON.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Engine condition Starter OFF signal Battery voltage

Threshold Value After engine starting Not detected ≥8V

Time Needed for Diagnosis: 180000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Starter OFF signal Battery voltage

Threshold Value Detected ≥8V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CX:DTC P0513 INCORRECT IMMOBILIZER KEY 1. OUTLINE OF DIAGNOSIS DTC

Item

P0513

Incorrect Immobilizer Key

P1570 P1571

Antenna Reference Code Incompatibility

P1572

IMM Circuit Failure (Except Antenna Circuit)

P1574

Key Communication Failure

P1576 P1577

EGI Control Module EEPROM IMM Control Module EEPROM

P1578

Meter Failure

Outline of diagnosis Incorrect immobilizer key (Use of unregistered key in body integrated unit) Faulty antenna Reference code incompatibility between body integrated unit and ECM Communication failure between body integrated unit and ECM Failure of body integrated unit to verify key (transponder) ID code or transponder failure ECM malfunctioning Body integrated unit malfunctioning Reference code incompatibility between body integrated unit and combination meter

2. ENABLE CONDITION When starting the engine.

3. GENERAL DRIVING CYCLE Perform the diagnosis only after starting the engine.

4. DIAGNOSTIC METHOD Judge as NG when the conditions for the outline of the diagnosis of the top are established.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CY:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR 1. OUTLINE OF DIAGNOSIS Detect the malfunction of microcomputer (RAM). When there is a problem in the main CPU normal RAM, or the sub CPU normal RAM, judge as NG. Judge as OK when both are operating properly. If it is possible to write data to the whole area of RAM in the initial routine, and is possible to read the same data, it is judged as OK, and if not, NG.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

Diagnosis with the initial routine.

3. GENERAL DRIVING CYCLE Perform the diagnosis as soon as the ignition switch is turned to ON.

4. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Write the specified value to RAM and then read.

Threshold Value The written value cannot be read.

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Write the specified value to RAM and then read.

Threshold Value The written value can be read.

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

CZ:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR 1. OUTLINE OF DIAGNOSIS Judge as NG when SUM value of ROM is outside the standard value.

2. ENABLE CONDITION Secondary Parameters Ignition switch

Enable Conditions ON

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD Abnormality Judgment Judge as NG if the criteria below are met. Judgment Value Malfunction Criteria SUM value of ROM

Threshold Value Standard

Time Needed for Diagnosis: Undetermined Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DA:DTC P0607 THROTTLE CONTROL SYSTEM CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Judge as NG when any one of the followings is established. (1) Monitoring IC operates abnormally. (Monitoring IC malfunction) (2) Input amplifier circuit of throttle position sensor 1 operates abnormally. (fourfold amplifier malfunction) (3) CPU operates abnormally. (Instruction/flow check) (4) A/D converter operates abnormally. (ADC malfunction) (5) EEPROM operates abnormally. (EEPROM malfunction) (6) Output IC operates abnormally. (Output driver malfunction)

2. COMPONENT DESCRIPTION

(1)

(9)

(8)

(12)

(7)

(10) (7)

(2)

(3)

(4)

(7) (13)

(5)

(11)

(7)

(6)

EN-08016

(1)

Throttle position sensor

(6)

(2) (3) (4) (5)

Throttle position sensor 1 Throttle position sensor 2 Accelerator pedal position sensor Accelerator pedal position sensor 1

(7) (8) (9)

Accelerator pedal position sensor 2 I/F circuit Amplifier circuit Engine control module (ECM)

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(10)

CPU

(11) (12) (13)

Monitoring IC EEPROM Output IC

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters (1) Battery voltage (2) Ignition switch (2) Battery voltage (3) Ignition switch (3) ETC control (4) Ignition switch (4) Battery voltage (5) Starter switch (5) Battery voltage (6) Ignition switch (6) Battery voltage

Enable Conditions ≥6V ON ≥6V ON Permitted ON ≥6V OFF >6V ON ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD Judge as OK and clear the NG when the malfunction criteria below are met. Judgment Value Malfunction Criteria (1) Monitoring IC operation

Threshold Value The result and estimated value match. 1: Lean λ < 1: Rich

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1)

Atmosphere

(3)

ZrO2

(4)

Ceramic heater

(2)

Exhaust gas

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Barometric pressure Rear oxygen sensor sub feedback Rear oxygen sensor output voltage – Feedback target voltage or rear oxygen sensor sub feedback compensation coefficient or rear oxygen sensor sub feedback compensation coefficient Elapsed time after starting the engine Engine coolant temperature Vehicle speed Amount of intake air Load change at 120°CA Front oxygen (A/F) sensor impedance Learning value of evaporation gas density Total time of operating canister purge Targeted lambda value load compensation coefficient

Enable Conditions ≥ 4096 ms ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) Execution –0.2 V — 0.1 V On Min. On Max. ≥ 60000 ms ≥ 75 °C (167 °F) ≥ 20 km/h (12.4 MPH) ≥ 8 g/s (0.28 oz/s) < 0.02 g/rev (0 oz/rev) 0 Ω — 50 Ω < 0.2 ≥ 19.9 s –0.05 — 0.050

4. GENERAL DRIVING CYCLE Perform diagnosis continuously at a constant speed of 20 km/h (12.4 MPH) or more after 60000 ms have passed since the engine started.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria λ value

Threshold Value < 0.85

Time Needed for Diagnosis: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria λ value

Threshold Value ≥ 0.85

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DE:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1) 1. OUTLINE OF DIAGNOSIS Detect that λ value remains high. Judge as NG when lambda value is abnormal in accordance with λ value of front oxygen (A/F) sensor and running conditions such as vehicle speed, amount of intake air, engine coolant temperature, sub feedback control, etc. λ value = Actual air fuel ratio/Theoretical air fuel ratio λ > 1: Lean λ < 1: Rich

2. COMPONENT DESCRIPTION (3) (1)

(A)

(2)

(2)

(C)

(B)

(D)

(4) EN-01693

(A) (D)

Electromotive force Rich

(B)

Air fuel ratio

(C)

Lean

(1)

Atmosphere

(3)

ZrO2

(4)

Ceramic heater

(2)

Exhaust gas

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

3. ENABLE CONDITION Secondary Parameters Time needed for all secondary parameters to be in enable conditions Battery voltage Barometric pressure Rear oxygen sensor sub feedback Rear oxygen sensor output voltage – Feedback target voltage or rear oxygen sensor sub feedback compensation coefficient or rear oxygen sensor sub feedback compensation coefficient Elapsed time after starting the engine Engine coolant temperature Vehicle speed Amount of intake air Load change at 120°CA Front oxygen (A/F) sensor impedance Learning value of evaporation gas density Total time of operating canister purge Targeted lambda value load compensation coefficient

Enable Conditions ≥ 4096 ms ≥ 10.9 V ≥ 75 kPa (563 mmHg, 22.2 inHg) Execution –0.2 V — 0.1 V On Min. On Max. ≥ 60000 ms ≥ 75 °C (167 °F) ≥ 20 km/h (12.4 MPH) ≥ 8 g/s (0.28 oz/s) < 0.02 g/rev (0 oz/rev) 0 Ω — 50 Ω < 0.2 ≥ 19.9 s –0.05 — 0.050

4. GENERAL DRIVING CYCLE Perform diagnosis continuously at a constant speed of 20 km/h (12.4 MPH) or more after 60000 ms have passed since the engine started.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria λ value

Threshold Value > 1.15

Time Needed for Diagnosis: 10000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria λ value

Threshold Value ≤ 1.15

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DF:DTC P1154 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 2 SENSOR 1) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1152.

DG:DTC P1155 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 2 SENSOR 1) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1153.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DH:DTC P1160 RETURN SPRING FAILURE 1. OUTLINE OF DIAGNOSIS Judge as NG when the valve is opened more than the default opening angle, but does not move to the close direction with the motor power stopped.

2. COMPONENT DESCRIPTION

(1)

(8)

(3)

(2)

S S (7) (6) (4)

(5)

EN-04463

(1) (2)

Opener spring Return spring

(4) (5)

Full closed stopper Throttle valve

(3)

Intermediate stopper

(6)

Gear

3. ENABLE CONDITION Secondary Parameters Battery voltage Throttle position sensor

Enable Conditions ≥6V Normal

4. GENERAL DRIVING CYCLE • Ignition switch ON → OFF • Ignition switch OFF → ON (Only after clearing memory)

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(7) (8)

DC motor Main and sub throttle position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction criteria Opening variation after continuity is set to OFF

Threshold value –4 kPa (–30 mmHg, –1.2 inHg) ≥ 30000 ms Not = 0 –10 °C (14 °F) — 70 °C (158 °F) ≥ –26.7 kPa (–200 mmHg, –7.9 inHg)

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DJ:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT) 1. OUTLINE OF DIAGNOSIS • Detects open or short circuit of EGR. • Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (5)

(1) (6)

(3) (2) (4)

EN-02051

(1) (2)

Engine control module (ECM) Computer unit (CPU)

(3) (4)

Detecting circuit Switch circuit

3. ENABLE CONDITION Secondary Parameters Elapsed time after starting the engine EGR valve target position Battery voltage

Enable Conditions ≥1s > 0 step ≥ 10.9 V

4. GENERAL DRIVING CYCLE Perform diagnosis continuously during EGR operation.

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(5) (6)

Battery voltage Main relay

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Terminal voltage level when ECM outputs OFF signal or Terminal voltage level when EGR operates

Threshold Value Low level

Low level

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal voltage level when ECM outputs OFF signal Terminal voltage level when EGR operates

Threshold Value High level High level

Time Needed for Diagnosis: 256 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DK:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT) 1. OUTLINE OF DIAGNOSIS • Detects open or short circuit of EGR. • Judge as NG when the ECM output level differs from the actual terminal level.

2. COMPONENT DESCRIPTION (5)

(1) (6)

(3) (2) (4)

EN-02051

(1) (2)

Engine control module (ECM) Computer unit (CPU)

(3) (4)

Detecting circuit Switch circuit

3. ENABLE CONDITION Secondary Parameters Elapsed time after starting the engine EGR valve target position Battery voltage

Enable Conditions ≥1s > 0 step ≥ 10.9 V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(5) (6)

Battery voltage Main relay

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Terminal voltage level when ECM outputs ON signal or Terminal voltage level when EGR operates

Threshold Value High level

High level

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Terminal voltage level when ECM outputs ON signal Terminal voltage level when EGR operates

Threshold Value Low level Low level

Time Needed for Diagnosis: 256 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DL:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1492.

DM:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1493.

DN:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1492.

DO:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1493.

DP:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1492.

DQ:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P1493.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DR:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of starter SW. Judge as OFF NG when it becomes after engine start despite no starter ON experience.

2. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment Judge as OFF NG when the following conditions are established. Judgment Value Malfunction Criteria Vehicle speed Starter ON signal Engine condition Battery voltage

Threshold Value < 1 km/h (0.6 MPH) Not detected Changed from before start to after start ≥8V

Time Needed for Diagnosis: Less than 1 second Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OFF OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Starter ON Starter ON diagnosis Battery voltage

Threshold Value Experienced No diagnosis experience ≥8V

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DS:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION 1. OUTLINE OF DIAGNOSIS Detect the open/short circuit of back-up power supply circuit. Judge as NG when the backup power voltage is low.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Voltage of back-up power supply Battery voltage Engine condition

Threshold Value Low ≥ 10.9 V After engine starting

Time Needed for Diagnosis: 2500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Voltage of back-up power supply Battery voltage Engine condition

Threshold Value High ≥ 10.9 V After engine starting

Time Needed for Diagnosis: Less than 1 second

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

DT:DTC P1570 ANTENNA 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

DU:DTC P1571 REFERENCE CODE INCOMPATIBILITY 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

DV:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

DW:DTC P1574 KEY COMMUNICATION FAILURE 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

DX:DTC P1576 EGI CONTROL MODULE EEPROM 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

DY:DTC P1577 IMM CONTROL MODULE EEPROM 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

DZ:DTC P1578 METER FAILURE 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P0513.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EA:DTC P1602 CONTROL MODULE PROGRAMMING ERROR 1. OUTLINE OF DIAGNOSIS Detect malfunctions of the catalyst advanced idling retard angle control. Judge as NG when ECM is not controlling the angle properly during catalyst advanced idling retard angle control. Judge as NG if there is exhaust gas temperature diagnosis, idle speed diagnosis and final ignition timing diagnosis and if any of them is NG. • Exhaust temperature diagnosis Judge as NG when the estimated exhausted gas temperature in 14 seconds after the cold start is below the specified value. • Idle speed diagnosis Judge as NG when actual engine speed is not close to target engine speed after terminating the retard angle control. • Final ignition timing diagnosis Judge as NG when actual retard amount is under the specified value at cold start.

2. ENABLE CONDITION Secondary Parameters Atmospheric pressure Battery voltage Cold start diagnosis Vehicle speed Misfire in 200 engine revs. Elapsed time after starting the engine

Enable Conditions ≥ 75 kPa (563 mmHg, 22.2 inHg) ≥ 10.9 V Incomplete < 2 km/h (1.2 MPH) –200 rpm) Continuous time of (actual retard amount > 20 °CA)

Threshold Value ≥ 6000 ms ≥ 0 ms

Time Needed for Diagnosis: 14 seconds Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Continuous time of (Target engine speed – Actual engine speed > –200 rpm) Continuous time of (actual retard amount > 20 °CA)

Threshold Value < 6000 ms < 0 ms

Time Needed for Diagnosis: Less than 1 second • Final ignition timing diagnosis Abnormality Judgment Judge as NG when the following conditions are established with diagnosis enable conditions successful. Judgment Value Malfunction Criteria Continuous time of (Standard ignition timing – Actual ignition timing ≤ 0 °CA)

Threshold Value > 5000 ms

Time Needed for Diagnosis: 5000 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. Normality Judgment Judge as OK and clear the NG if the following conditions are established. Judgment Value Malfunction Criteria Continuous time of (Standard ignition timing – Actual ignition timing > 0 °CA)

Threshold Value > 1000 ms

Time Needed for Diagnosis: 1000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EB:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the oil flow control solenoid valve. Judge as NG when the current is small even though the duty signal is large.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current

Threshold value ≥ 10.9 V ≥ 99.61 % < 0.306 A

Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Threshold value Battery voltage ≥ 10.9 V Target current value of the oil flow control ≥ 0.14 A solenoid valve |Target current value of the oil flow con< 0.08 A trol solenoid valve – Oil flow control solenoid valve control current value|

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EC:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of oil flow control solenoid valve. Judge as NG when the current is large even though the duty signal is small.

2. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current

Threshold value ≥ 10.9 V < 0.39 % ≥ 0.306 A

Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Threshold value Battery voltage ≥ 10.9 V |Target current value of the oil flow con< 0.08 A trol solenoid valve – Oil flow control solenoid valve control current value|

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

ED:DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of the oil flow control solenoid valve. Judge as NG when the current is small even though the duty signal is large.

2. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current

Threshold Value ≥ 10.9 V ≥ 99.61 % < 0.306 A

Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Target current value of the oil flow control solenoid valve |Target current value of the oil flow control solenoid valve – oil flow control solenoid valve control current value|

Threshold Value ≥ 10.9 V ≥ 0.14 A < 0.08 A

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EE:DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect open or short circuit of oil flow control solenoid valve. Judge as NG when the current is large even though the duty signal is small.

2. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

3. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

4. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Battery voltage Oil flow control solenoid valve control duty Oil control solenoid valve control present current

Threshold Value ≥ 10.9 V < 0.39 % ≥ 0.306 A

Time Needed for Diagnosis: 2000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage |Target current value of the oil flow control solenoid valve – oil flow control solenoid valve control current value|

Threshold Value ≥ 10.9 V < 0.08 A

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EF:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P2088.

EG:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P2089.

EH:DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P2090.

EI: DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2) 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P2091.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EJ:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of fuel system from the size of the sub feedback learning value. Control the sub feedback learning and judge as NG when the learning value is in the lean zone.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

3. ENABLE CONDITION Secondary Parameters Conditions for carrying out the sub feedback learning Continuous time when all conditions are established.

Enable Conditions Completed ≥1s

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km/h (50 MPH) or more.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Sub feedback learning value

Threshold value < –0.032

Time Needed for Diagnosis: 5 s × 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Sub feedback learning value

Threshold value ≥ –0.032 + 0

Time Needed for Diagnosis: 5 s

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EK:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH (BANK 1) 1. OUTLINE OF DIAGNOSIS Detect the malfunction of fuel system from the size of the sub feedback learning value. Sub feedback learning is being performed. When the learning value goes to the rich side, judge as NG.

2. COMPONENT DESCRIPTION

(E) (3)

V

(1)

(F)

(A)

(2)

(2) (C)

(B)

(D)

EN-01696

(A) (D)

Electromotive force Lean

(B) (E)

Air fuel ratio Theoretical air fuel ratio

(C) (F)

Rich Comparative voltage

(1)

Atmosphere

(2)

Exhaust gas

(3)

Electromotive force

3. ENABLE CONDITION Secondary Parameters Conditions for carrying out the sub feedback learning Continuous time when all conditions are established.

Enable Conditions Completed ≥1s

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously when the vehicle is idling or running at a constant speed of 80 km/h (50 MPH) or more.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Sub feedback learning value

Threshold value ≥ 0.031

Time Needed for Diagnosis: 5 s × 1 time(s) Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Sub feedback learning value

Threshold value < 0.031 + 0

Time Needed for Diagnosis: 5 s

EL:DTC P2098 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 2 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P2096.

EM:DTC P2099 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 2 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC P2097.

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EN:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/ PERFORMANCE 1. OUTLINE OF DIAGNOSIS Judge as NG when the motor current becomes large or drive circuit is heated.

2. COMPONENT DESCRIPTION 12V

12V

(1)

(6)

(2)

(3)

(7)

(4)

(2)

(5) EN-01867

(1) (2) (3)

Engine control module (ECM) Detecting circuit Overcurrent detection circuit

(4) (5)

Drive circuit Temperature detection circuit

3. ENABLE CONDITION Secondary Parameters Under control of electronic throttle control CPU communication line sub → main normal judgment

Enable Conditions ON Normal

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(6) (7)

Electronic throttle control relay Motor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Motor current or Drive circuit inner temperature

Threshold value >8A > 175°C (347°F)

Time Needed for Diagnosis: 512 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Motor current Drive circuit inner temperature

Threshold Value ≤8A ≤ 175°C (347°F)

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EO:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Judge as NG when the electronic throttle control power is not supplied even when ECM sets the electronic throttle control relay to ON.

2. COMPONENT DESCRIPTION 12V

12V

(1)

(4)

(2)

(5)

(3)

EN-01868

(1) (2)

Engine control module (ECM) Voltage detection circuit

(3) (4)

Drive circuit Electronic throttle control relay

3. ENABLE CONDITION Secondary Parameters Battery voltage Electronic throttle control relay output

Enable Conditions ≥ 11 V ON

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(5)

Motor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Motor power voltage

Threshold value ≤5V

Time Needed for Diagnosis: 352 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Motor power voltage

Threshold value >5V

Time Needed for Diagnosis: 2000 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EP:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Judge as NG when the electronic throttle control power is supplied even when ECM sets the electronic throttle control relay to OFF.

2. COMPONENT DESCRIPTION 12V

12V

(1)

(4)

(2)

(5)

(3)

EN-01868

(1) (2)

Engine control module (ECM) Voltage detection circuit

(3) (4)

Drive circuit Electronic throttle control relay

3. ENABLE CONDITION Secondary Parameters Battery voltage Electronic throttle control relay output

Enable Conditions ≥6V OFF

4. GENERAL DRIVING CYCLE • When ignition switch ON → OFF • Ignition switch OFF → ON (Only after clearing memory)

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(5)

Motor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Motor power voltage

Threshold value ≥5V

Time Needed for Diagnosis: 600 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Motor power voltage

Threshold value 20.116 °

or Throttle opening angle when the ignition switch is ON – Throttle minimum stop position

< 0.887 °

Time Needed for Diagnosis: 8 ms — 80 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Throttle sensor opening angle at full close point learning

Threshold value ≥ 9.884 ° and ≤ 20.116 °

Throttle opening angle when the ignition switch is ON – Throttle minimum stop position

≥ 0.887 °

Time Needed for Diagnosis: 8 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

ER:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Sensor 1 input voltage

Threshold value < 0.217 V

Time Needed for Diagnosis: 100 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Sensor 1 input voltage

Threshold value ≥ 0.217 V

Time Needed for Diagnosis: 100 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

ES:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D” CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 1. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Sensor 1 input voltage

Threshold value ≥ 4.783 V

Time Needed for Diagnosis: 32 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Sensor 1 input voltage

Threshold value < 4.783 V

Time Needed for Diagnosis: 32 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

ET:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT LOW INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Sensor 2 input voltage

Threshold value < 0.217 V

Time Needed for Diagnosis: 100 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Sensor 2 input voltage

Threshold value ≥ 0.217 V

Time Needed for Diagnosis: 100 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EU:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH “E” CIRCUIT HIGH INPUT 1. OUTLINE OF DIAGNOSIS Detect the open or short circuit of accelerator pedal position sensor 2. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria Sensor 2 input voltage

Threshold value ≥ 4.783 V

Time Needed for Diagnosis: 100 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria Sensor 2 input voltage

Threshold value < 4.783 V

Time Needed for Diagnosis: 100 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EV:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH “A”/“B” VOLTAGE CORRELATION 1. OUTLINE OF DIAGNOSIS Judge as NG when the signal level of throttle position sensor 1 is different from the throttle position sensor 2.

2. COMPONENT DESCRIPTION (3) (4)

(1)

(2)

EN-01859

(1) (2)

Throttle position sensor 1 signal Throttle position sensor 2 signal

(3)

Throttle position sensor

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Engine control module (ECM)

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the NG range of judgment value detail

Details of Judgment Value

(Y5)

(NG area)

(Y4) Sensor output difference (˚)

(Y3) (Y2) (OK area)

(Y1)

0 0 (X1) (X2)

(X3)

(X4)

Throttle position sensor 1 opening angle (˚)

EN-08032

(X1) (X4)

2.125 ° 31.625 °

(X2)

4.25 °

(X3)



(Y1) (Y4)

5.15 ° 10.4 °

(Y2) (Y5)

6.15 ° 12.4 °

(Y3)

8.28 °

Time Needed for Diagnosis: 212 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the OK range of judgment value detail

Time Needed for Diagnosis: 24 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EW:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH “D”/“E” VOLTAGE CORRELATION 1. OUTLINE OF DIAGNOSIS Judge as NG when the signal level of throttle position sensor 1 is different from the throttle position sensor 2.

2. COMPONENT DESCRIPTION (4) (1)

(2)

(3)

EN-01861

(1)

Engine control module (ECM)

(2)

Accelerator pedal position sensor 1 signal

(3)

Accelerator pedal position sensor 2 signal

3. ENABLE CONDITION Secondary Parameters Ignition switch Battery voltage

Enable Conditions ON ≥6V

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

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(4)

Accelerator pedal position sensor

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the NG range of judgment value detail

Details of Judgment Value

(Y5)

(Y4) Sensor output difference (˚)

(NG area)

(Y3) (Y2) (Y1) (OK area)

0 0

(X1)

(X2)

(X3)

(X4)

Accelerator pedal position sensor 1 opening angle (˚) EN-08033

(X1) (X4)

0.6 ° 4°

(X2)

1.2 °

(X3)



(Y1) (Y4)

1.465 ° 2.455 °

(Y2) (Y5)

1.597 ° 3.116 °

(Y3)

1.663 °

Time Needed for Diagnosis: 116 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Signal difference between two sensors

Threshold Value Within the OK range of judgment value detail

Time Needed for Diagnosis: 116 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EX:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE 1. OUTLINE OF DIAGNOSIS Detect the malfunction of barometric pressure sensor output property. Judge as NG when the barometric pressure sensor output is largely different from the intake manifold pressure at engine start.

2. COMPONENT DESCRIPTION The barometric pressure sensor is built into the ECM.

3. ENABLE CONDITION Secondary Parameters Engine speed Vehicle speed

Enable Conditions < 300 rpm < 1 km/h (0.6 MPH)

4. GENERAL DRIVING CYCLE Perform the diagnosis once at ignition switch ON.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction criteria |Barometric pressure – Intake manifold pressure| |Intake manifold pressure at engine start – Intake manifold pressure|

Threshold value ≥ 26.7 kPa (200 mmHg, 7.9 inHg) < 1.3 kPa (9.99 mmHg, 0.4 inHg)

Time Needed for Diagnosis: 328 ms Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction criteria |Barometric pressure – Intake manifold pressure|

Threshold value < 26.7 kPa (200 mmHg, 7.9 inHg)

Time Needed for Diagnosis: 262 ms

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EY:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW 1. OUTLINE OF DIAGNOSIS Detect the open/short circuit of the barometric pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION The barometric pressure sensor is built into the ECM.

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 1.707 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 1.707 V

Time Needed for Diagnosis: Less than 1 second

GD(H6DO)-213

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

EZ:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH 1. OUTLINE OF DIAGNOSIS Detect the open/short circuit of the barometric pressure sensor. Judge as NG if out of specification.

2. COMPONENT DESCRIPTION The barometric pressure sensor is built into the ECM.

3. ENABLE CONDITION Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Always perform the diagnosis continuously.

5. DIAGNOSTIC METHOD • Abnormality Judgment If the duration of time while the following conditions are met is longer than the time indicated, judge as NG. Judgment Value Malfunction Criteria Output voltage

Threshold Value ≥ 4.234 V

Time Needed for Diagnosis: 500 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Output voltage

Threshold Value < 4.234 V

Time Needed for Diagnosis: Less than 1 second

GD(H6DO)-214

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

FA:DTC U0073 CAN FAILURE, BUS ‘OFF’ DETECTION 1. OUTLINE OF DIAGNOSIS Detect malfunction of CAN communication. When CAN communications is not possible, and CAN communications with TCM, VDC CM and body integrated unit is not possible, judge as NG if data from the TCM, VDC CM and body integrated unit are not normal.

2. COMPONENT DESCRIPTION ECM, TCM, VDC CM and body integrated unit are connected by high speed CAN.

(Common Specifications) CAN Protocol 2.0 B (Active) Frame Format: 11 Bit ID Frame (Standard Frame) (High speed CAN) Conforms to ISO11898 Communication Speed: 500 kbps

3. ENABLE CONDITIONS Secondary Parameters

Enable Conditions

None

4. GENERAL DRIVING CYCLE Perform the diagnosis continuously after starting the engine.

5. DIAGNOSTIC METHOD • Abnormality Judgment Judge as NG when the following conditions are established. Judgment Value Malfunction Criteria Battery voltage Starter switch Engine bus off flag or error warning flag or ID received from control module connected to driving system CAN or Data updated from control module connected to driving system CAN

Threshold Value > 10.9 V OFF run set (error) None during 500 milliseconds None during 2000 milliseconds

Time Needed for Diagnosis: 2 seconds Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs. • Normality Judgment Judge as OK and clear the NG if the continuous time while the following conditions are established is more than the predetermined time. Judgment Value Malfunction Criteria Battery voltage Starter switch Engine bus off flag or error warning flag ID received from control module connected to driving system CAN Data updated from control module connected to driving system CAN

Threshold Value > 10.9 V OFF run clear (No error) Yes Yes

Time Needed for Diagnosis: 1000 ms Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

GD(H6DO)-215

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Diagnostic Trouble Code (DTC) Detecting Criteria GENERAL DESCRIPTION

FB:DTC U0101 CAN (TCU) DATA NOT LOADED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

FC:DTC U0122 CAN (VDC) DATA NOT LOADED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

FD:DTC U0140 CAN (BCU) DATA NOT LOADED 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

FE:DTC U0402 CAN (TCU) DATA ABNORMAL 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

FF:DTC U0416 CAN (VDC) DATA ABNORMAL 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

FG:DTC U0422 CAN (BCU) DATA ABNORMAL 1. OUTLINE OF DIAGNOSIS NOTE: For the detection standard, refer to DTC U0073.

GD(H6DO)-216

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2010 LEGACY SERVICE MANUAL

QUICK REFERENCE INDEX

TRANSMISSION SECTION

This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of 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.

CONTROL SYSTEMS

CS

CONTINUOUSLY VARIABLE TRANSMISSION

CVT

CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

CVT(diag)

AUTOMATIC TRANSMISSION

5AT

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5AT(diag)

MANUAL TRANSMISSION AND DIFFERENTIAL

6MT

CLUTCH SYSTEM

CL

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD.

G2460BE5

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CONTROL SYSTEMS

CS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Page General Description ...................................................................................2 AT Shift Lock Control System ....................................................................7 Select Lever .............................................................................................21 Select Cable .............................................................................................41 AT Shift Lock Solenoid and “P” Range Switch .........................................52 Body Integrated Unit ................................................................................55 MT Gear Shift Lever .................................................................................56 MT Gear Shift Cable ................................................................................63 MT Gear Select Cable ..............................................................................72 General Diagnostic Table .........................................................................96

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General Description CONTROL SYSTEMS

1. General Description A: COMPONENT 1. AT SELECT LEVER

(8)

(2)

(1) (9)

(10)

(4)

(3)

(11) (12) (5)

(15)

T2

(13)

(16)

(6)

(14) (7) (20) (17)

(21) (18)

(19)

(22) (23) (25)

T2 (24)

(26) (27) (29)

(28) T1 (30)

CS-01244

CS-2

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General Description CONTROL SYSTEMS (1) (2)

Cover grip AT Button ASSY-AT

(13) (14)

Clamp push nut Clamp push nut

(25) (26)

Snap pin Washer

(3)

Clamp grip pin

(15)

Clamp pin

(27)

Select cable (AT model)

(4)

Grip ASSY sub

(16)

Spacer pin guide

(28)

Select cable (CVT model)

(5)

Rod COMPL

(17)

Plate COMPL

(29)

Clamp

(6)

Cover grip AT

(18)

Shaft control

(30)

Nut

(7)

Indicator ASSY

(19)

Spacer pin guide

(8) (9) (10) (11) (12)

Arm ASSY Selector lever COMPL Plate guide Rod detent Detent spring

(20) (21) (22) (23) (24)

Rod shift lock Cushion solenoid Solenoid unit Gasket Spacer plate

CS-3

Tightening torque:N·m (kgf-m, ft-lb) T1: 7.5 (0.8, 5.5) T2: 18 (1.8, 13.3)

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General Description CONTROL SYSTEMS

2. 6MT GEAR SHIFT LEVER

(9) (7)

(1)

(16) (17)

(2)

(15)

(18) (8)

(11)

(14) T2 (3)

(13)

(12) (9)

T2 T3

(4)

(5) T1

T3 (10)

(7) (6) (9) (8)

T1 CS-01198

CS-4

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General Description CONTROL SYSTEMS (1) (2)

Shift knob Shift boot

(9) (10)

Clamp Clamp cable

(3)

Console front cover ASSY

(11)

Select bracket

(4) (5) (6) (7)

Gear shift lever ASSY Cover cable ASSY Plate cable ASSY MT gear select cable (identification tape color: green)

(12) (13) (14) (15)

Shift bracket Dust cover Snap pin Shift lever COMPL

(8)

MT gear shift cable (identification tape color: yellow)

(16)

Spring pin

(17) (18)

Shifter arm No. 2 Shift bracket

Tightening torque:N·m (kgf-m, ft-lb) T1: 7.5 (0.8, 5.5) T2: 15 (1.5, 11.1) T3: 18 (1.8, 13.3)

B: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Use SUBARU genuine fluid, grease or equivalent. Do not mix fluid and grease of different grades or manufacturers. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Apply grease onto sliding or revolving surfaces before installation. • Before installing the O-ring or snap ring, apply a sufficient amount of fluid to avoid damage and deformation. • Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise. • Before disconnecting electrical connectors, be sure to disconnect the negative terminal from battery.

CS-5

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General Description CONTROL SYSTEMS

C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 1B022XU0

DESCRIPTION SUBARU SELECT MONITOR III KIT

REMARKS Used for troubleshooting the electrical system.

ST1B022XU0

41099AJ000 FRONT MOUNT(Newly adopted tool) ING H4

Used for holding and balancing the engine unit.

ST41099AJ000

10004AA180 (SUBARU genuine part)

Engine hanger rear

• Used for lifting engine. (ENGINE HANGER REAR for turbo model) • For 2.5 L non-turbo model.

ST10004AA180

2. GENERAL TOOL TOOL NAME Engine crane Circuit tester

REMARKS Used for lifting engine. Used for measuring resistance and voltage.

CS-6

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AT Shift Lock Control System CONTROL SYSTEMS

2. AT Shift Lock Control System A: LOCATION

(4)

(7)

(1)

(3)

(2)

(6)

(5)

CS-01199

(1)

TCM (“P” range)

(4)

(2) (3)

Body integrated unit Stop light switch

(5)

Key cylinder (with built-in key warning switch) Solenoid unit

(6)

“P” range switch

(7)

Key lock solenoid

(3)

(2) (1) CS-01200

CS-01201 (6)

(4)

(7)

(5)

CS-01193

CS-7

CS-01083

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AT Shift Lock Control System CONTROL SYSTEMS

B: ELECTRICAL SPECIFICATION

A : B 280 side 7 6 5 4 3 17 16 15 14 13 12 11 27 26 25 24 23 22 21 34 33 32 31

2 1 10 9 8 20 19 18 30 29 28

B : B 281 side

C:

7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 35 34 33 32 31 30 29 28

i 84

side

D : i171 side

6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 27 26 25 24 23 22 21 20 19 18 17 30 29 28 35 34 33 32 31

7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 25 24 23 22 21 20 19 18 31 30 29 28 27 26

CS-01085

Connector No.

Terminal No.

Input/Output signal Measured value and measuring conditions

Battery power supply

B281 i84

6 6

11 V or more

Ignition power supply

i171

17 25

11 V or more when ignition switch is at ON or START. 11 V or more when ignition switch is at ACC.

TCM (“P” range)

B281

20 28

Pulse signal

Stop light switch

B280

10

“P” range switch

B281

21

Solenoid unit output

B281

5

Key warning switch signal

B280

4

Key lock solenoid output

B281

Item

Ground

B280

3 4 1

B281 i84 i171

31 1 29

11 V or more when stop light switch is ON. 0 V when stop light switch is OFF. Less than 1.5 V when select lever is in “P” range. 8 V or more when select lever is in other positions than “P” range. 11 V or more when shift lock is released. 0 V when shift lock is operating. 11 V or more when key is inserted. 0 V when key is removed. 9 V or more (unlock) *1 9 V or more (lock) *1



*1

: Measuring condition Key warning switch OFF ON ON ON

“P” range switch — OFF ON ON

Ignition switch — — OFF ON

CS-8

Output Unlock Lock Unlock Lock

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AT Shift Lock Control System CONTROL SYSTEMS

Output signal for key interlock solenoid (unlock) (V)

20

10

0

10 0

10

20

30

40

(ms)

150

200

(ms)

CS-01191

Output signal for key interlock solenoid (lock) (V)

20

10

0

10 0

50

100

CS-9

CS-01192

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AT Shift Lock Control System CONTROL SYSTEMS

C: WIRING DIAGRAM (10)

(1) (5)

OFF ACC ON

(2)

(6)

(4) (7)

(8)

(3)

(9)

CS-01086

(1) (2) (3) (4)

Ignition switch Stop light switch Key warning switch Body integrated unit

(5) (6) (7) (8)

TCM (shift range information) Key lock solenoid Solenoid unit “P” range switch

CS-10

(9) (10)

Battery VDC (vehicle speed information)

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AT Shift Lock Control System CONTROL SYSTEMS

D: INSPECTION 1. SHIFT LOCK OPERATION 1

2

Step CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to ON. 2) Using the Subaru Select Monitor, check whether communication to all systems can be executed normally. CHECK SHIFT LOCK. 1) Turn the ignition switch to ON. 2) Shift the select lever to “P” range.

Check Yes Is the system name displayed? Go to step 2.

While brake pedal is not depressed, is it possible to move the select lever from the “P” range to other ranges?

Perform the inspection of “SELECT LEVER CANNOT BE LOCKED OR RELEASED”.

Go to step 4.

3

CHECK SHIFT LOCK.

While brake pedal is depressed, is it possible to move the select lever from the “P” range to other ranges?

4

CHECK SHIFT LOCK. Shift the select lever to “N” range.

Is it possible to move the select Go to step 5. lever from the “N” range to the “P” range?

CS-11

No Perform the inspection following the diagnostic procedure in the LAN section. Go to step 3.

Perform the inspection of “SELECT LEVER CANNOT BE LOCKED OR RELEASED”.

Perform the inspection of “SELECT LEVER CANNOT BE LOCKED OR RELEASED”.

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AT Shift Lock Control System CONTROL SYSTEMS

5

Step CHECK SHIFT LOCK. 1) Shift the select lever to “N” range. 2) Turn the ignition switch to OFF.

Check While brake pedal is depressed, is it possible to move the select lever from the “N” range to the “P” range?

6

CHECK KEY INTERLOCK. Can the ignition key be 1) Shift the select lever to other than “P” range. removed? 2) Turn the ignition switch to OFF.

7

CHECK KEY INTERLOCK. Shift the select lever to “P” range.

Can the ignition key be removed?

CS-12

Yes Go to step 6.

No Perform the inspection of “SELECT LEVER CANNOT BE LOCKED OR RELEASED”.

Go to step 7.

Perform the inspection of “KEY INTERLOCK CANNOT BE LOCKED OR RELEASED”.

AT shift lock sys- Perform the tem is normal. inspection of “KEY INTERLOCK CANNOT BE LOCKED OR RELEASED”.

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AT Shift Lock Control System CONTROL SYSTEMS

2. BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT NOTE: For the DC power supply circuit, refer to “WIRING DIAGRAMS”. IGNITION SWITCH OFF ACC ON

SBF-6

MAIN SBF

B ACC IG

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 7, 8, 9, 10, 11 AND 12

*2

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 3, 4, 5 AND 6

BATTERY

No. 18

No. 17

*1

*1

No. 31

No. 12

SBF-7

J/ C J/ C

*

*1

i82

2

i98

A : B280

C:

i84

B : B281

D:

i171

BODY INTEGRATED UNIT

i82

J/C

B 31

A1

C1

D29

B6

C6

D 25

D 17

3

i97

*2 *2

B491

E

E

i98 B491

i97 1 2 3 4 5

1 2 3 4 5 6 7 8 9 10 11 12

A : B280 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B : B281 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

C:

i84

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

D : i171

5 6 14 15 16 25 26 27 33 34 35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

CS-01219

1

2

Step Check Yes CHECK DTC OF BODY INTEGRATED UNIT. Is the DTC of power line disRepair or replace it Check DTC of body integrated unit. played on body integrated unit? according to the DTC. CHECK HARNESS CONNECTOR BETWEEN Is the voltage 9 — 16 V? Go to step 3. BODY INTEGRATED UNIT AND CHASSIS GROUND. 1) Turn the ignition switch to ON. 2) Measure the voltage between body integrated unit and chassis ground. Connector & terminal (i84) No. 6 (+) — Chassis ground (–): (i171) No. 17 (+) — Chassis ground (–): (i171) No. 25 (+) — Chassis ground (–): (B281) No. 6 (+) — Chassis ground (–):

CS-13

No Go to step 2.

Check the harness for open or short circuit between body integrated unit and battery, and check the fuses.

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AT Shift Lock Control System CONTROL SYSTEMS

3

4

Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 4. BODY INTEGRATED UNIT AND CHASSIS GROUND. 1) Turn the ignition switch to OFF. 2) Measure the harness resistance between the body integrated unit and chassis ground. Connector & terminal (B280) No. 1 — Chassis ground: (B281) No. 31 — Chassis ground: (i84) No. 1 — Chassis ground: (i171) No. 29 — Chassis ground: CHECK FOR POOR CONTACT. Is there poor contact of connec- Repair the poor tor? contact.

CS-14

No Repair the open circuit of harness between the body integrated unit and chassis ground.

End.

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AT Shift Lock Control System CONTROL SYSTEMS

3. SELECT LEVER CANNOT BE LOCKED OR RELEASED BATTERY No. 8

SBF-8

No. 18

MAIN SBF

STOP LIGHT SWITCH J/C

KEY WARNING SWITCH

*12 *

3

*12 *

2 3

B512

4

B65

A4

A10

B350

A : B280

BODY INTEGRATED UNIT

B 28

B 20

B5

B 21

B : B281

P RANGE SWITCH SHIFT LOCK SOLENOID

*1

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 5 AND 6

*2

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 3, 4, 7 AND 8

CV

: CVT MODEL

AT

: 5AT MODEL

B116

B491

B:

J/C

B20 B17

B116

AT CV

4

4

2

B21 B18

3

1

B55 TCM

E

B116

B65

1 3

1 2 3 4 5 6 7 8

2 4

B:

B55

B350 1 2 3 4 5 6

CV

1 2 3 4 5 6 7 8 9 10 11 12 13 28 29 30 31 32 21 22 21 22

B491

B512

1 2 3 4 5

1 2 3 4 5 6 7 8

B : B281

A : B280 1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B:

B55

AT

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

CS-01202

1

Step Check CHECK BODY INTEGRATED UNIT POWER Is there an abnormal condition? SUPPLY AND GROUND CIRCUIT.

CS-15

Yes Follow the procedures to perform inspection and repair.

No Go to step 2.

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AT Shift Lock Control System CONTROL SYSTEMS

2

3

4

5

Step CHECK CURRENT DATA. 1) Connect the Subaru Select Monitor. 2) Shift the select lever to “P” range. 3) Turn the ignition switch to ON. 4) Select the current data display and display «P SW». CHECK CURRENT DATA. Select the current data display and display «Stop Light Switch».

Check Is the display “ON” in the “P” range and “OFF” in ranges other than “P”?

Yes Go to step 3.

Go to step 4. Is “ON” displayed when the brake pedal is depressed and “OFF” displayed when the brake pedal is released? CHECK BODY INTEGRATED UNIT DTC. Is there a DTC of a current mal- Follow the DTC to Check the DTC of the body integrated unit when function? perform inspection the brake pedal is pressed and when it is and repair. released. (Hold each condition for 5 seconds or more.) CHECK CURRENT DATA. Is “ON” displayed when the Go to step 6. Select the current data display and display brake pedal is depressed and «Shift Lock Solenoid». “OFF” displayed when the brake pedal is released?

6

CHECK CURRENT DATA. Select the current data display and display «Shift Position».

7

CHECK CURRENT DATA. Is a figure equivalent to the Go to step 12. 1) Select the current data display and display speedometer being indicated? «Front Wheel Speed». 2) Start the engine. 3) Raise vehicle speed gradually up to approximately 20 km/h.

8

CHECK HARNESS BETWEEN BODY INTE- Is the harness normal? GRATED UNIT AND “P” RANGE SWITCH. 1) Disconnect the connector from body integrated unit. 2) Disconnect the connector of “P” range switch. 3) Check for open circuit of harness, short circuit to battery or short circuit to ground between the body integrated unit and “P” range switch. Connector & terminal (B281) No. 21 — (B116) No. 1:

Is the display “7” in the “P” range and other than “7” in ranges other than “P”?

CS-16

Go to step 7.

Repair or replace the harness between the body integrated unit and the “P” range switch.

No Go to step 8.

Go to step 11.

Go to step 5.

Replace the body integrated unit.

Check the following items. • Inhibitor switch • Harness between inhibitor switch and TCM • TCM input signal • TCM CAN communication • Body integrated unit CAN receive Check the following items. • Wheel speed sensor • VDC/ABS CAN communication • Body integrated unit CAN receive Replace the wheel speed sensor, VDC/ABS, or body integrated unit, or both. Go to step 9.

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AT Shift Lock Control System CONTROL SYSTEMS

9

10

11

12

Step CHECK HARNESS BETWEEN “P” RANGE SWITCH AND CHASSIS GROUND. Measure the resistance of harness between “P” range switch and chassis ground. Connector & terminal (B116) No. 2 — Chassis ground: CHECK “P” RANGE SWITCH. Measure the resistance between “P” range switch connector terminals. Terminals No. 2 — No. 1: CHECK STOP LIGHT SWITCH INPUT SIGNAL. 1) Disconnect the connector from body integrated unit. 2) Measure the voltage between the body integrated unit connector terminal and chassis ground. Connector & terminal (B280) No. 10 (+) — Chassis ground (–): CHECK SOLENOID UNIT OPERATION. Connect the battery to the solenoid unit connector terminal, and operate the solenoid unit. Terminals No. 3 (+) — No. 4 (–):

Check Is it less than 10 Ω?

Yes Go to step 10.

No Repair the harness between the “P” range switch and chassis ground.

Is it less than 10 Ω in the “P” range, and 1 MΩ or more in ranges other than “P”?

Replace the body integrated unit.

Is the voltage 11 V or more when the brake pedal is depressed, and less than 1 V when not pressed?

Replace the body integrated unit.

Replace the “P” range switch. Check the stop light system.

Does the solenoid unit operate Check the lock Replace the solenormally? mechanism of the noid unit.

CS-17

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AT Shift Lock Control System CONTROL SYSTEMS

No. 18

4. KEY INTERLOCK DOES NOT LOCK OR RELEASE

BATTERY

KEY WARNING SWITCH

3 4

A4

B350

A : B280 BODY INTEGRATED UNIT

P RANGE SWITCH

B4

B3

B 21

B : B281

1 2

4

6

5

B350 B116 B491 J/C

KEY LOCK SOLENOID

E

B350 1 2 3 4 5 6

B116

1 2 3 4 5 6 7 8

A : B280

B : B281 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

B491 1 2 3 4 5

CS-01241

1

Step Check Yes CHECK BODY INTEGRATED UNIT POWER Is there an abnormal condition? Follow the proceSUPPLY AND GROUND CIRCUIT. dures to inspect

CS-18

No Go to step 2.

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AT Shift Lock Control System CONTROL SYSTEMS

2

3

4

5

6

7

8

9

Step CHECK CURRENT DATA. 1) Connect the Subaru Select Monitor. 2) Shift the select lever to “P” range. 3) Turn the ignition switch to ON. 4) Select the current data display and display «P SW». CHECK CURRENT DATA. 1) Select the current data display and display the «Key-lock warning SW». 2) Turn the ignition switch to OFF. CHECK CURRENT DATA. 1) Turn the ignition switch to OFF. 2) Select the current data display and display «Key locking output». CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND “P” RANGE SWITCH. 1) Disconnect the connector from body integrated unit. 2) Disconnect the connector of “P” range switch. 3) Check for open circuit of harness, short circuit to battery or short circuit to ground between the body integrated unit and “P” range switch. Connector & terminal (B281) No. 21 — (B116) No. 1: CHECK HARNESS BETWEEN “P” RANGE SWITCH AND CHASSIS GROUND. Measure the resistance of harness between “P” range switch and chassis ground. Connector & terminal (B116) No. 2 — Chassis ground: CHECK “P” RANGE SWITCH. Measure the resistance between “P” range switch connector terminals. Terminals No. 2 — No. 1: CHECK HARNESS BETWEEN BATTERY AND KEY WARNING SWITCH AND BODY INTEGRATED UNIT. 1) Disconnect the connector from body integrated unit. 2) Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B280) No. 4 (+) — Chassis ground (–): CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND KEY LOCK SOLENOID. 1) Disconnect the connector from body integrated unit. 2) Disconnect the connector of key lock solenoid. 3) Check for open circuit of harness, short circuit to battery or short circuit to ground between the body integrated unit and key lock solenoid. Connector & terminal (B281) No. 3 — (B350) No. 5: (B281) No. 4 — (B350) No. 6:

Check Is the display “ON” in the “P” range and “OFF” in ranges other than “P”?

Yes Go to step 3.

No Go to step 5.

Does the display change from “ON” to “OFF” when the key is inserted and removed?

Go to step 4.

Go to step 8.

Is the display “unLock” in the Go to step 9. “P” range and “Lock” in ranges other than “P”?

Go to step 5.

Is the harness normal?

Repair or replace Go to step 6. the harness between the body integrated unit and the “P” range switch.

Is it less than 10 Ω?

Go to step 7.

Repair the harness between the “P” range switch and chassis ground.

Is it less than 10 Ω in the “P” range, and 1 MΩ or more in ranges other than “P”?

Replace the body integrated unit.

Is the display 11 V or more when the key is inserted, and less than 1 V with the key removed?

Replace the body integrated unit.

Replace the “P” range switch. Check the following items. • Key warning switch • Harness/fuse • Ignition circuit

Is the harness normal?

Repair or replace Go to step 10. the harness between the body integrated unit and the key lock solenoid.

CS-19

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AT Shift Lock Control System CONTROL SYSTEMS

10

11

Step CHECK KEY LOCK SOLENOID OPERATION. Connect the battery to the key lock solenoid connector terminal, and operate the solenoid. CHECK OUTPUT OF BODY INTEGRATED UNIT. 1) Connect all connectors. 2) Insert the key. 3) Shift the select lever to “P” range. 4) Turn the ignition switch to OFF. 5) Using an oscilloscope, measure the voltage between body integrated unit and chassis ground. Connector & terminal Lock (B281) No. 4 (+) — Chassis ground (–): Unlock (B281) No. 3 (+) — Chassis ground (–):

Check Does the key lock solenoid operate normally?

Yes Go to step 11.

Is the lock output voltage 9 V Check the lock when the grip button of select mechanism of the lever is pressed? steering lock body. Is the unlock output voltage 9 V when the grip button of select lever is released?

CS-20

No Replace the key lock solenoid. Replace the body integrated unit.

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Select Lever CONTROL SYSTEMS

3. Select Lever A: REMOVAL 1) Set the vehicle on a lift. 2) Shift the select lever to “N” range. 3) Disconnect the ground cable from battery. 4) Lift up the vehicle. 5) Remove the rear exhaust pipe. • 2.5 L non-turbo model

• 3.6 L model

6) Remove the heat shield cover.

CS-01104

7) Remove the cable from arm assembly.

(B)

(A) CS-01174

(A) Nut (B) Arm ASSY

CS-21

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Select Lever CONTROL SYSTEMS

8) Raise the claw of the clamp and remove the cable.

(A)

CS-01175

(A) Claw

9) Lower the vehicle. 10) Lower the cover grip AT vertically toward the lever. : (A)

CS-01203

(A) Claws (3 places)

CS-22

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Select Lever CONTROL SYSTEMS

11) Remove the clamp grip pin.

CS-01204

12) Remove the grip assembly.

CS-01205

CS-23

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Select Lever CONTROL SYSTEMS

13) Turn over the rubber and remove the console front cover assembly.

CS-01206

(A)

CS-01207

(A) Hooks (4 places)

14) Remove the console box.

CS-24

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Select Lever CONTROL SYSTEMS

15) Remove the harness clip from the select lever.

CS-01208

16) Disconnect the harness connector.

CS-01099

CS-25

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Select Lever CONTROL SYSTEMS

17) Remove the four bolts to remove the select lever assembly.

CS-01209

B: INSTALLATION 1) Set the select lever to vehicle body. 2) Tighten the four mounting bolts to attach the select lever to the vehicle body.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CS-01209

CS-26

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Select Lever CONTROL SYSTEMS

3) Connect the harness connector.

CS-01099

4) Install the harness clip to the select lever.

CS-01208

5) Shift the select lever to “N” range. 6) Install the console box and the console front cover assembly.

CS-27

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Select Lever CONTROL SYSTEMS

7) Accessing from the button side of the grip, attach the clamp grip pin.

CS-01101

8) Install the cover grip AT securely. NOTE: After installation, check that the cover grip AT cannot be detached.

CS-01102

CS-28

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Select Lever CONTROL SYSTEMS

9) Insert the grip assembly to the select lever and press it down until a click is heard.

CS-01210

10) After installation of grip, check the following points. • The grip will not come off. • The button on the grip operates normally. 11) Lift up the vehicle. 12) Shift the range select lever to “N” range. 13) Secure the cable to the bracket. 14) Adjust the select cable position. 15) After adjustment, confirm that the select lever operates properly at all range positions using the shift lock release button. 16) Install the heat shield cover.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CS-01104

17) Install the rear exhaust pipe. • 2.5 L non-turbo model

• 3.6 L model

CS-29

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Select Lever CONTROL SYSTEMS

18) Inspect the following items. If a malfunction is found in the inspection, adjust the select cable or inhibitor switch (CVT model). (1) The shift lock operates normally. (2) Engine starts when the select lever is in “P” or “N” range, but not in other ranges. (3) Back-up light illuminates when the select lever is in the “R” range, but not in other ranges. (4) Select lever and indicator positions are matched.

C: DISASSEMBLY 1. GRIP ASSY 1) Remove the cover grip AT.

: (A) CS-01189

(A) Claws (3 places)

2) Remove the button assembly-AT.

(A)

CS-01190

(A) Claw

3) Remove the rod COMPL.

CS-30

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Select Lever CONTROL SYSTEMS

2. AT SELECT LEVER ASSEMBLY 1) Remove the spacer.

CS-01105

2) Remove the gasket.

CS-01106

CS-31

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Select Lever CONTROL SYSTEMS

3) Insert a flat tip screwdriver with a thin tip under the connector and disconnect the harness connector from the plate COMPL.

CS-01107

4) Remove the harness from the plate COMPL.

CS-01108

CS-32

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Select Lever CONTROL SYSTEMS

5) Raise the claw with a flat tip screwdriver with a thin tip and remove the solenoid unit.

CS-01109

6) Using a flat tip screwdriver with a thin tip, remove the solenoid unit terminals from the connector.

(A)

3 2 1 8 7 6 5 4 (A)

CS-01110

(A) Solenoid unit terminals

CS-33

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Select Lever CONTROL SYSTEMS

7) Remove the clamp push nut. NOTE: Replace the clamp push nut with a new part.

CS-01111

8) Pull out shaft control.

CS-01112

CS-34

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Select Lever CONTROL SYSTEMS

9) Remove the clamp push nut. NOTE: Replace the clamp push nut with a new part.

CS-01113

10) Pull out spacer pin guide.

CS-01114

CS-35

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Select Lever CONTROL SYSTEMS

11) Remove the clamp pin.

CS-01115

12) Remove the spacer pin guide.

CS-01116

CS-36

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Select Lever CONTROL SYSTEMS

13) Remove the select lever COMPL from the plate COMPL.

CS-01117

14) Remove the arm assembly.

(A)

(B)

CS-01118

(A) Arm ASSY (B) Selector lever COMPL

CS-37

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Select Lever CONTROL SYSTEMS

15) Remove the guide assembly from the select lever COMPL.

CS-01211

16) Remove the rod detent and detent spring from the select lever COMPL.

CS-01212

CS-38

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Select Lever CONTROL SYSTEMS

3. INDICATOR ASSY 1) Disconnect the harness connector from the console front cover assembly.

CS-01213

2) Remove the four screws and remove the indicator assembly from the console front cover assembly.

CS-01214

CS-39

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Select Lever CONTROL SYSTEMS

D: ASSEMBLY 1) Clean all the parts before assembly. 2) Apply Multemp D or equivalent to each part. 3) Assemble in the reverse order of disassembly. NOTE: Insert the solenoid unit terminals to the harness connector.

(A)

3 2 1 8 7 6 5 4 (B) CS-01179

(A) Solenoid unit (color code: blue) (B) Solenoid unit (color code: black)

4) After installation, check the following points. • The select indicator matches the select lever position when the select lever is changed from “P” range to “D” range. • The select lever position and the position mark match each other. • Operating force to move the select lever from “P” to “D” range.

E: INSPECTION 1) Inspect the removed parts by comparing with new ones for deformation, damage and wear. Repair or replace if defective. 2) Inspect the select lever assembly operating condition before assembly. Normal if it operates smoothly.

CS-40

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Select Cable CONTROL SYSTEMS

4. Select Cable A: REMOVAL 1) Set the vehicle on a lift. 2) Shift the select lever to “N” range. 3) Disconnect the ground cable from battery. 4) Lift up the vehicle. 5) Remove the front exhaust pipe and rear exhaust pipe. • 2.5 L model • 3.6 L model 6) Remove the heat shield cover.

CS-01104

CS-41

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Select Cable CONTROL SYSTEMS

7) Remove the snap pin and washer from the shifter arm and remove the select cable from the shifter arm. • CVT model

(B)

(E)

(C) (D)

(A) CS-01128

(A) (B) (C) (D) (E)

Shifter arm Snap pin Select cable Plate ASSY Washer

• AT model

(B) (A)

(D)

(C)

(E)

CS-01129

(A) (B) (C) (D) (E)

Shifter arm Snap pin Select cable Plate ASSY Washer

CS-42

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Select Cable CONTROL SYSTEMS

8) Remove the plate assembly from the transmission case. • CVT model

(A) (B)

CS-01130

(A) Select cable (B) Plate ASSY

• AT model

(B)

(A)

CS-01131

(A) Select cable (B) Plate ASSY

CS-43

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Select Cable CONTROL SYSTEMS

9) Disconnect the cable from arm assembly.

(B)

(A) CS-01174

(A) Nut (B) Arm ASSY

10) Raise the claw of clamp to remove the cable from bracket.

(A)

CS-01175

(A) Claw

11) Remove the select cable from plate assembly.

CS-44

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Select Cable CONTROL SYSTEMS

B: INSTALLATION 1) Install the select cable to plate assembly.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

T

T CS-01176

2) Install the select cable to range select lever. 3) Install the plate assembly to transmission.

Tightening torque: T: 25 N·m (2.5 kgf-m, 18.4 ft-lb) • CVT model

T

(A) (B)

CS-01132

(A) Select cable (B) Plate ASSY

CS-45

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Select Cable CONTROL SYSTEMS

• AT model

T

(A) (B)

CS-01133

(A) Select cable (B) Plate ASSY

4) Install the washer and snap pin to the shifter arm. • CVT model

(B)

(E)

(C) (D)

(A) CS-01128

(A) (B) (C) (D) (E)

Shifter arm Snap pin Select cable Plate ASSY Washer

CS-46

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Select Cable CONTROL SYSTEMS

• AT model

(B) (A)

(D)

(C)

(E)

CS-01129

(A) (B) (C) (D) (E)

Shifter arm Snap pin Select cable Plate ASSY Washer

5) Install new clamp paying attention to the installing direction.

(A)

C

C

(B) CS-01134

(A) Clamp (B) Forward

CS-47

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Select Cable CONTROL SYSTEMS

6) Insert the tip of inner cable into connector hole of select lever, and fix the cable to bracket.

CS-01135

7) Shift the select lever to the “N” range, and then adjust the select cable position. 8) Install the heat shield cover.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CS-01104

9) Install the front exhaust pipe and rear exhaust pipe. • 2.5 L model • 3.6 L model

CS-48

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Select Cable CONTROL SYSTEMS

C: INSPECTION Check the removed cable and replace or adjust if damaged, rusty or malfunctioning. 1) Check that the inner cable moves smoothly without drag. 2) Check the inner cable for damage and rust. 3) Check the outer cable for damage, bends and cracks. 4) Check the boot for damage, cracks and deterioration. 5) Shift the select lever from “P” range to “D” range. Check the existence of feel to contact the detents in each range. If the detents cannot be felt or the position pointer is improperly aligned, adjust the cable. 6) Check that the starter motor rotates when the select lever is set to “P” or “N” range. 7) Check the back-up light illumination when the select lever is in “R” range. 8) Check the shift lock operation when the select lever is in “P” range.

D: ADJUSTMENT 1) Set the vehicle on a lift. 2) Shift the select lever to “N” range. 3) Lift up the vehicle. 4) Remove the front exhaust pipe and rear exhaust pipe. • 2.5 L non-turbo model • 3.6 L model 5) Remove the heat shield cover.

CS-01104

CS-49

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Select Cable CONTROL SYSTEMS

6) Loosen the nuts on both sides.

(A)

(B)

CS-01136

(A) Nut A (B) Nut B

7) Turn the nut B until it lightly touches the connector.

(B)

(A) (C)

(D)

(E)

(F) CS-01137

(A) (B) (C) (D) (E) (F)

Forward side Select lever Connector Nut B Contact point Nut A

CS-50

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Select Cable CONTROL SYSTEMS

8) Set a spanner wrench to the nut B so that it does not rotate, and then tighten the nut A.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(A)

(B)

CS-01138

(A) Nut A (B) Nut B

9) After the completion of adjustment, confirm that the select lever operates normally at all ranges. 10) Install in the reverse order of removal.

CS-51

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AT Shift Lock Solenoid and “P” Range Switch CONTROL SYSTEMS

5. AT Shift Lock Solenoid and “P” Range Switch A: REMOVAL 1. SOLENOID UNIT 1) Remove the AT select lever. 2) Remove the spacer and gasket. 3) Using a flat tip screwdriver with a thin tip, remove the harness connector from the plate COMPL.

CS-01107

4) Raise the claw using a flat tip screwdriver with a thin tip, and remove the solenoid unit from the plate COMPL.

CS-01139

CS-52

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AT Shift Lock Solenoid and “P” Range Switch CONTROL SYSTEMS

5) Using a flat tip screwdriver with a thin tip, remove the solenoid unit terminals from the harness connector.

(A)

3 2 1 8 7 6 5 4 (A)

CS-01110

(A) Solenoid unit terminals

2. “P” RANGE SWITCH For the removal of “P” range switch, refer to the procedure for AT select lever.

B: INSTALLATION Install in the reverse order of removal. NOTE: Insert the solenoid unit terminals to the harness connector.

(A)

3 2 1 8 7 6 5 4 (B) CS-01179

(A) Solenoid unit (color code: blue) (B) Solenoid unit (color code: black)

CS-53

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AT Shift Lock Solenoid and “P” Range Switch CONTROL SYSTEMS

C: INSPECTION 1

Step CHECK SOLENOID UNIT. Measure the resistance of solenoid unit connector terminals. Terminals No. 4 — No. 3:

2

CHECK SOLENOID UNIT. Connect the battery to the solenoid unit connector terminals, and then operate the solenoid. Terminals No. 3 (+) — No. 4 (–):

3

CHECK “P” RANGE SWITCH. 1) Shift the select lever to “P” range. 2) Measure the resistance between “P” range switch connector terminals. Terminals No. 1 — No. 2: CHECK “P” RANGE SWITCH. 1) Shift the select lever to other than “P” range. 2) Measure the resistance between “P” range switch connector terminals. Terminals No. 1 — No. 2:

4

Check Is the resistance 27.6 — 30.5 Ω?

No Replace the solenoid unit. Does the solenoid unit operate Go to step 3. Replace the solenormally? noid unit. Is the resistance less than 1 Ω? Go to step 4. Replace the “P” range switch. Is the resistance 1 MΩ or Normal operation. Replace the “P” more? range switch.

CS-54

Yes Go to step 2.

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Body Integrated Unit CONTROL SYSTEMS

6. Body Integrated Unit A: NOTE Refer to “Body Integrated Unit” for removal and installation procedure.

CS-55

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MT Gear Shift Lever CONTROL SYSTEMS

7. MT Gear Shift Lever A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Remove the center exhaust pipe and rear exhaust pipe. (non-turbo model) 5) Remove the center exhaust pipe (rear) and rear exhaust pipe. (turbo model) 6) Remove the heat shield cover.

CS-01140

7) Remove the plate cable assembly.

CS-01141

CS-56

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MT Gear Shift Lever CONTROL SYSTEMS

8) Remove the spring at the MT gear shift cable by expanding it and pulling down, and remove the MT gear shift cable from the gear shift lever assembly. CAUTION: Be careful not to deform the cable inner.

(A)

CS-01142

(A) MT gear shift cable

9) Remove the MT gear select cable from the gear shift lever assembly by pulling it in the direction of arrow in the figure. CAUTION: Be careful not to deform the cable inner.

(A) CS-01143

(A) MT gear select cable

CS-57

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MT Gear Shift Lever CONTROL SYSTEMS

10) Remove the cover cable assembly.

CS-01144

11) Lower the vehicle. 12) Remove the gear shift knob. 13) Remove the console front cover assembly and console box. 14) Remove the bolts, and then remove the gear shift lever assembly from the vehicle. NOTE: The MT gear shift lever cannot be disassembled.

CS-01145

CS-58

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MT Gear Shift Lever CONTROL SYSTEMS

B: INSTALLATION 1) Install the gear shift lever assembly.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CS-01145

2) Lift up the vehicle. 3) Install the cover cable assembly.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

CS-01144

CS-59

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MT Gear Shift Lever CONTROL SYSTEMS

4) Connect the MT gear shift cable and MT gear select cable. CAUTION: • Be careful not to deform the cable inner. • Do not twist the cable inner excessively. (A)

(B)

CS-01146

(A) MT gear shift cable (B) MT gear select cable

5) Install the plate cable assembly.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

CS-01141

CS-60

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MT Gear Shift Lever CONTROL SYSTEMS

6) Install the heat shield cover.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CS-01140

7) Install the center exhaust pipe and rear exhaust pipe. (non-turbo model) 8) Install the center exhaust pipe (rear) and rear exhaust pipe. (turbo model) 9) Lower the vehicle. 10) Install the console front cover assembly and the console box. 11) Install the gear shift knob. 12) Make sure the gears can be shifted accurately into each gear. Adjust the MT gear select lever, if the gears cannot be shifted correctly.

CS-61

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MT Gear Shift Lever CONTROL SYSTEMS

C: INSPECTION 1) Check for any deformed, damaged or worn part. Repair or replace as necessary Compare the removed parts with new parts to check if there are damages or not. 2) Check that the lever cannot be moved to the reverse position unless the slider is pulled up. 3) Check that the lever can be moved to the reverse position when the slider is pulled up to maximum. 4) Check that the shift lever returns to the initial position when it is moved to “N” from the condition in 3).

1

3

5

N

SELECT DIRECTION

2

4

6

R CS-01177

CS-62

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MT Gear Shift Cable CONTROL SYSTEMS

8. MT Gear Shift Cable A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Remove the center exhaust pipe and rear exhaust pipe. (non-turbo model) 5) Remove the center exhaust pipe (rear) and rear exhaust pipe. (turbo model) 6) Remove the heat shield cover.

CS-01140

7) Remove the clamp cable and take out the MT gear shift cable from the clamp.

(A)

CS-01147

(A) Clamp cable

CS-63

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MT Gear Shift Cable CONTROL SYSTEMS

8) Remove the dust cover from transmission body. (A)

CS-01148

(A) Dust cover

9) Apply a mark on the top end of the MT gear shift cable. 10) Remove the snap pin from the shift lever COMPL.

(A)

CS-01149

(A) Snap pin

CS-64

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MT Gear Shift Cable CONTROL SYSTEMS

11) Remove the shift bracket and MT gear shift cable as a single unit from the transmission body.

(A)

(B)

CS-01150

(A) MT gear shift cable (B) Shift bracket

12) Remove the plate cable assembly.

CS-01141

CS-65

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MT Gear Shift Cable CONTROL SYSTEMS

13) Remove the spring at the MT gear shift cable by expanding it and pulling down, and remove the MT gear shift cable from the gear shift lever assembly. CAUTION: Be careful not to deform the cable inner.

(A)

CS-01142

(A) MT gear shift cable

14) Remove the clamp which holds the MT gear shift cable.

(A)

(B)

CS-01151

(A) Clamp (B) MT gear shift cable

15) Pull out the MT gear shift cable from cover cable assembly.

CS-66

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MT Gear Shift Cable CONTROL SYSTEMS

B: INSTALLATION 1) When replacing the new MT gear shift cable, secure it to shift bracket with the clamps, be careful not to mistake the installing direction.

(A)

(B) (C)

CS-01152

(A) Old MT gear shift cable (B) New MT gear shift cable (C) Shift bracket

2) Install the MT gear shift cable and shift bracket as a single unit onto transmission. CAUTION: • Do not bend MT gear shift cable at a sharp angle. • Do not twist the cable inner excessively. NOTE: When installing the MT gear shift cable, make sure that the mark or blue mark on the cable faces up.

(C)

(A)

(B)

CS-01153

(A) MT gear shift cable (B) Shift bracket (C) Mark

CS-67

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MT Gear Shift Cable CONTROL SYSTEMS

3) Tighten the shift bracket with specified torque.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

(A)

(B)

CS-01150

(A) MT gear shift cable (B) Shift bracket

4) Install the snap pin.

(A)

CS-01154

(A) Snap pin

CS-68

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MT Gear Shift Cable CONTROL SYSTEMS

5) Install the dust cover to the transmission body.

Tightening torque: 15 N·m (1.5 kgf-m, 11.1 ft-lb) (A)

CS-01148

(A) Dust cover

6) Insert the MT gear shift cable into the cover cable assembly, and secure it with the clamp.

(A)

(B)

CS-01151

(A) Clamp (B) MT gear shift cable

7) Connect the MT gear shift cable.

CS-69

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MT Gear Shift Cable CONTROL SYSTEMS

8) Install the plate cable assembly.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

CS-01141

9) Insert the MT gear shift cable into clamp cable, and install to the transmission.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

(A)

CS-01147

(A) Clamp cable

CS-70

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MT Gear Shift Cable CONTROL SYSTEMS

10) Install the heat shield cover.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CS-01140

11) Install the center exhaust pipe and rear exhaust pipe. (non-turbo model) 12) Install the center exhaust pipe (rear) and rear exhaust pipe. (turbo model) 13) Lower the vehicle. 14) Make sure the gears can be shifted accurately into each gear.

CS-71

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MT Gear Select Cable CONTROL SYSTEMS

9. MT Gear Select Cable A: REMOVAL CAUTION: Do not reuse the MT gear select cable which removed from select lever COMPL. 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Remove the air intake duct. • Non-turbo model

• Turbo model

4) Remove the intercooler and the intercooler stay. (turbo model) 5) Remove the air intake boot assembly. (non-turbo model) 6) Remove the throttle body. (non-turbo model) 7) Remove the bolt and remove the engine harness connector. (non-turbo model)

CS-01220

CS-72

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MT Gear Select Cable CONTROL SYSTEMS

8) Remove the engine harness connector from the engine hanger rear. (non-turbo model)

CS-01221

9) Remove the engine hanger rear. (non-turbo model)

AT-05449

CS-73

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MT Gear Select Cable CONTROL SYSTEMS

10) Install the engine hanger rear for turbo model. (non-turbo model) Part No. 10004AA180 Engine hanger rear

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

AT-05450

11) Lift up the vehicle. 12) Remove the center exhaust pipe and rear exhaust pipe. (non-turbo model) 13) Remove the center exhaust pipe (rear) and rear exhaust pipe. (turbo model) 14) Remove the heat shield cover.

CS-01140

15) Lower the vehicle.

CS-74

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MT Gear Select Cable CONTROL SYSTEMS

16) Remove the nuts from left and right transmission mounting brackets.

AT-05622

17) Set an engine crane to the vehicle. CAUTION: When lifting the engine, make sure that the lift chain does not contact sensors. 18) Remove the stopper rod.

AT-05416

CS-75

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MT Gear Select Cable CONTROL SYSTEMS

19) Lift the engine slightly and remove the bolts of engine front mounting.

AT-05628

20) Remove the bolt and nuts of engine front mounting and remove the engine mounting.

AT-05629

CS-76

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MT Gear Select Cable CONTROL SYSTEMS

21) Temporarily install the ST by using two bolts. ST 41099AJ000 FRONT MOUNTING H4

ST

CS-01157

22) Lift the engine even higher, and attach the bolts and nuts to the vehicle. CAUTION: Do not lift up higher than enough level to install the ST to avoid damage to the hoses and pipes inside the engine room. NOTE: • If it is difficult to pull out the stud bolt from transmission mounting bracket, shake the engine unit slightly while lifting up.

CS-01158

CS-77

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MT Gear Select Cable CONTROL SYSTEMS

23) Tighten the mounting bolts on the engine side.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-05630

24) Put aside the engine crane. 25) Lift up the vehicle. 26) Set the transmission jack to the transmission. 27) Remove the clamp cable and take out the MT gear select cable from the clamp.

(A)

CS-01147

(A) Clamp cable

CS-78

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MT Gear Select Cable CONTROL SYSTEMS

28) Remove the mounting bolts from the front crossmember and rear crossmember, and lower the transmission. CAUTION: When lowering the transmission, make sure that the transmission jack does not come off from the transmission.

CS-01159

29) Insert a spanner between the selector lever COMPL and the MT gear select cable and remove the MT gear select cable by raising the handle. NOTE: • Use a spanner with 11 to 13 in size. • The thickness of the spanner must not exceed 6 mm (0.2 in). (A)

(C)

(B) (B) (A)

(C) (B) CS-01160

(A) MT gear select cable (B) Spanner (C) Forward

CS-79

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MT Gear Select Cable CONTROL SYSTEMS

30) Remove the MT gear select cable and select bracket as an assembly from the transmission body.

(B)

(A)

CS-01161

(A) Select bracket (B) MT gear select cable

31) Remove the plate cable assembly.

CS-01141

CS-80

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MT Gear Select Cable CONTROL SYSTEMS

32) Disconnect the MT gear select cable. CAUTION: Be careful not to deform the cable inner. NOTE: To remove the MT gear select cable, push it in the direction of arrow.

(A) CS-01162

(A) MT gear select cable

33) Remove the clamp which holds the MT gear select cable.

(A) (B)

CS-01163

(A) Clamp (B) MT gear select cable

34) Pull out the MT gear select cable from the cover cable assembly. CAUTION: Do not bend the MT gear select cable sharply.

CS-81

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MT Gear Select Cable CONTROL SYSTEMS

B: INSTALLATION CAUTION: • Do not reuse the MT gear select cable which removed from select lever COMPL. • Do not bend the MT gear select cable sharply. • Do not twist the inner cable excessively. 1) Remove the MT gear select cable from the select bracket. CAUTION: Check for assembling position before removing the MT gear select cable from the select bracket.

(A) (B)

CS-01164

(A) MT gear select cable (B) Select bracket

CS-82

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MT Gear Select Cable CONTROL SYSTEMS

2) Set to the new MT gear select cable to the select bracket and secure it with the clamp. CAUTION: Be careful not to mistake the MT gear select cable installing direction.

(C)

(A)

(B)

CS-01165

(A) MT gear select cable (B) Select bracket (C) Clamp

3) Install the MT gear select cable and select bracket as a single unit to the transmission body.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

(B)

(A)

CS-01161

(A) Select bracket (B) MT gear select cable

CS-83

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MT Gear Select Cable CONTROL SYSTEMS

4) Install the MT gear select cable to the select lever COMPL. (A)

(B)

CS-01166

(A) Selector lever COMPL (B) MT gear select cable

5) Measure the exposed length (a) of MT gear select cable. If out of specification, adjust the MT gear select cable.

Exposed length (a) of MT gear select cable: Specification: 11 mm (0.4 in)

(a)

CS-01167

6) Connect the MT gear select cable.

CS-84

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MT Gear Select Cable CONTROL SYSTEMS

7) Install the plate cable assembly.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

CS-01141

8) Insert the MT gear select cable into clamp cable, and install to the transmission.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

(A)

CS-01147

(A) Clamp cable

CS-85

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MT Gear Select Cable CONTROL SYSTEMS

9) Raise the transmission jack, install the front crossmember and rear crossmember.

Tightening torque: T1: 75 N·m (7.6 kgf-m, 55.3 ft-lb) T2: 140 N·m (14.3 kgf-m, 103.3 ft-lb)

T1

T1

T2 T2

CS-01168

10) Take out the transmission jack. 11) Install the heat shield cover.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CS-01140

12) Install the center exhaust pipe and rear exhaust pipe. (non-turbo model) 13) Install the center exhaust pipe (rear) and rear exhaust pipe. (turbo model) 14) Lower the vehicle.

CS-86

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MT Gear Select Cable CONTROL SYSTEMS

15) Lift the engine slightly and remove the bolts from the ST (FRONT MOUNTING H4).

AT-05630

16) Remove the bolts and nuts, and remove the ST (FRONT MOUNTING H4).

AT-05633

CS-87

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MT Gear Select Cable CONTROL SYSTEMS

17) Place and temporarily attach the front engine mounting with bolts.

AT-05634

18) Tighten the bolts and nuts of front engine mounting. NOTE: Always start tightening from the bolts on the engine side.

Tightening torque: T1: 25 N·m (2.5 kgf-m, 18.4 ft-lb) T2: 45 N·m (4.6 kgf-m, 33.2 ft-lb)

T1

T1

T2

CS-01169

CS-88

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MT Gear Select Cable CONTROL SYSTEMS

19) Install the stopper rod.

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb)

CS-01155

20) Attach the nuts to the left and right transmission mounting brackets.

Tightening torque: 45 N·m (4.6 kgf-m, 33.2 ft-lb)

AT-05622

CS-89

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MT Gear Select Cable CONTROL SYSTEMS

21) Remove the engine hanger rear for turbo model and install the engine hanger rear for non-turbo model. (non-turbo model)

Tightening torque: T1: 16 N·m (1.6 kgf-m, 11.8 ft-lb) T2: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

T1

T2

AT-05637

22) Install the throttle body. (non-turbo model) 23) Install the engine harness connectors to the engine hanger rear. (non-turbo model) 24) Connect the engine harness connectors, and install harness bracket to the engine hanger rear. (non-turbo model)

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

CS-01220

25) Install the air intake boot assembly. (non-turbo model) 26) Install the intercooler stay and the intercooler. (turbo model)

CS-90

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MT Gear Select Cable CONTROL SYSTEMS

27) Install the air intake duct. • Non-turbo model

• Turbo model

28) Make sure the gears can be shifted accurately into each gear.

C: INSPECTION 1) Check that exposed length (a) of MT gear select cable is within specification.

Exposed length (a) of MT gear select cable: Specification: 11 mm (0.4 in)

(a)

CS-01167

2) If it is not within the specification, perform the adjustment.

CS-91

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MT Gear Select Cable CONTROL SYSTEMS

D: ADJUSTMENT NOTE: To adjust the MT gear select cable, two workers are required. (Only the step 7) requires two workers.) 1) Shift the select lever to 6th. 2) Remove the plate cable assembly.

CS-01141

3) Disconnect the MT gear select cable. NOTE: To remove the MT gear select cable, push it in the direction of arrow.

(A) CS-01162

(A) MT gear select cable

CS-92

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MT Gear Select Cable CONTROL SYSTEMS

4) Measure the exposed length (a) of MT gear select cable.

(a)

CS-01167

5) With the slider (green) moved in the direction of arrow, release the lock piece (pink) using a flat tip screwdriver or equivalent tool. CAUTION: The lock piece is made of plastic and fragile. If the lock piece is damaged, replace the MT gear select cable with a new one. NOTE: Turn the MT gear select cable to 180 degrees and push and raise the claw of the lock piece by sliding the slider in the direction of arrow.

(D)

(C)

(C) (B)

(A)

CS-01170

(A) (B) (C) (D)

Slider Lock piece Claw Flat tip screwdriver

CS-93

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MT Gear Select Cable CONTROL SYSTEMS

6) With the lock piece released, connect the MT gear select cable to the select lever.

(B) (C)

(A)

CS-01171

(A) Lock piece (B) Select lever (C) MT gear select cable

7) Operate the select lever to the Rev side, hold the lever so that the exposed length (a) of the MT gear select cable is 11 mm (0.4 in), and push in the lock piece. NOTE: While pulling up the gear shift lever assembly slider, operate the lever to the Rev side.

(C) (B)

(a) (A)

CS-01172

(a) (A) (B) (C)

Exposed length 11 mm (0.4 in) Lock piece Select lever MT gear select cable

8) Shifting to 5th ←→ 6th, and then to Rev, check for any drag. 9) If no abnormal condition is found for the shift and select operations, restore the vehicle.

CS-94

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MT Gear Select Cable CONTROL SYSTEMS

10) If the shift operation is not smooth, readjust the exposed length (a) of the MT gear select cable referring to the figure below.

1st

3rd

(A)

5th

(a)

(B)

(B)

(A) 2nd

4th

6th

Rev (C)

CS-01173

(a) (A) (B) (C)

Exposed length of MT gear select cable Extending exposed length of gear select cable Shrinking exposed length of gear select cable Reference for exposed length (a)

• If 5th or 6th gear cannot be selected when cable is pressed to reverse lock bracket: → Extend the exposed length (a) of MT gear select cable. • If select lever does not move along the cranking line when it is operated from 4th to 5th gear: → Shorten the exposed length (a) of MT gear select cable. NOTE: If only the cable adjustment cannot rectify the condition, replace the MT gear select cable.

CS-95

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General Diagnostic Table CONTROL SYSTEMS

10.General Diagnostic Table A: INSPECTION Symptoms AT select lever

Possible cause Starter does not run. Back-up light does not illuminate. AT shift lock system does not operate normally. Manual mode can not be set.

MT gear shift lever (6MT)

Up-shift is not engaged at manual mode. Down-shift is not engaged at manual mode. Cannot shift into reverse. Shifted to 6th though it shifted to reverse. Can shift into reverse when the slider is not pulled up. Slider cannot be pulled up or sticks in the pulledup position.

CS-96

Corrective action Adjust the select cable and inhibitor switch, or inspect the circuit. Adjust the select cable and inhibitor switch, or inspect the circuit. Adjust the select cable and inhibitor switch, or inspect the circuit. Adjust the mode switch and select lever, or inspect the circuit. Check the shift-up switch and circuit. Check the shift-down switch and circuit. Adjust the MT gear select cable. Adjust or replace the MT gear select cable. Adjust or replace the MT gear select cable. • Check the shift link system of the transmission. • Adjust or replace the MT gear select cable.

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CONTINUOUSLY VARIABLE TRANSMISSION

CVT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.

Page General Description ...................................................................................3 CVTF ........................................................................................................35 Differential Gear Oil ..................................................................................40 Variator Chain Break-in ............................................................................44 AWD ON/OFF Switching Mode ................................................................45 Road Test .................................................................................................46 Stall Test ..................................................................................................47 Time Lag Test ..........................................................................................48 Secondary Pressure (Line Pressure) Test ...............................................49 Transfer Clutch Pressure Test .................................................................52 Automatic Transmission Assembly ..........................................................54 Transmission Mounting System ...............................................................85 Extension Case Oil Seal ..........................................................................88 Differential Side Retainer Oil Seal ............................................................90 Inhibitor Switch .........................................................................................94 Secondary Speed Sensor ......................................................................101 Primary Speed Sensor ...........................................................................103 Front Wheel Speed Sensor ....................................................................105 Secondary Pressure Sensor ..................................................................107 Control Valve Body ................................................................................109 Transmission Harness ...........................................................................119 Transmission Control Module (TCM) .....................................................122 CVTF Cooler Pipe and Hose ..................................................................124 CVT Oil Cooler .......................................................................................133 Air Breather Hose ...................................................................................134 Drive Plate ..............................................................................................135 Preparation for Overhaul ........................................................................137 Torque Converter Assembly ..................................................................138 Extension Case ......................................................................................140 Rear Drive Shaft .....................................................................................143 Transfer Clutch .......................................................................................148 Transfer Reduction Driven Gear ............................................................160 Parking Pawl ..........................................................................................165 Intermediate Case ..................................................................................167 CVTF Filter .............................................................................................172 Reverse Brake Assembly .......................................................................173 Forward Clutch Assembly ......................................................................182 Reduction Driven Gear ...........................................................................202 Transmission Control Device .................................................................209 Transmission Case ................................................................................213 Primary Pulley and Secondary Pulley ....................................................227 Variator Chain ........................................................................................242 Drive Pinion Shaft Assembly ..................................................................243

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CONTINUOUSLY VARIABLE TRANSMISSION

44. 45. 46. 47. 48. 49. 50. 51.

Front Differential Assembly ....................................................................264 Oil Pump ................................................................................................282 Oil Pump Chain ......................................................................................283 Converter Case Cover ...........................................................................291 Front Reduction Drive Gear ...................................................................299 Front Reduction Driven Gear .................................................................306 Converter Case ......................................................................................316 Diagnostics with Phenomenon ...............................................................319

CVT-2

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

1. General Description A: SPECIFICATION 1. TORQUE CONVERTER Model Type Stall torque ratio Nominal mm (in) Stall speed (at sea level)

2.5 L SOHC non-turbo Symmetric, 3-element, single stage, 2-phase torque converter 2.07 236 (9.29) 2,400 — 3,100

One-way clutch

Sprague type one-way clutch

2. OIL PUMP Type Driving method Number of teeth

Internal gear pump Driven by chain Inner rotor Outer rotor

8 9

3. TRANSMISSION CONTROL ELEMENT Type Multi-plate clutch Multi-plate brake

Forward continuously variable speed change, 1 reverse, planetary gear 1 sets 1 sets

4. TRANSMISSION GEAR RATIO Forward Rev

3.525 — 0.558 2.358

5. PLATE Number of input clutch drive plates Number of forward clutch drive plates Number of reverse brake drive plates

5 6 5

6. SELECTOR POSITION P (Park) R (Reverse) N (Neutral) D (Drive)

Transmission neutral, output shaft locked, engine start enabled Rev Transmission neutral, engine start enabled Forward continuously variable speed change

M (manual mode) (paddle shift + side)

Manual gear change 1st → 2nd → 3rd → 4th → 5th → 6th

M (manual mode) (paddle shift — side)

Manual gear change 1st ← 2nd ← 3rd ← 4th ← 5th ← 6th

CVT-3

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

7. HYDRAULIC CONTROL AND LUBRICATION Electronic hydraulic control (speed changed by signals of vehicle speed and accelerator opening angle) SUBARU CVT OIL FOR LINEARTRONIC (specified fluid) or equivalent CAUTION: Always use specified CVTF or equivalent. Using other fluid except for specified or equivalent will cause malfunction.

Type

Fluid

Fluid capacity 2 (US qt, Imp qt)

12.0 — 12.5 (12.7 — 13.2, 10.6 — 11.0)

Lubrication system

Forced feed lubrication with oil pump

8. COOLING AND HARNESS Liquid-cooler incorporated in radiator (except for OUTBACK) Liquid-cooler incorporated in radiator + air-cooler (OUTBACK) 12 poles 20 poles

Cooling system Inhibitor switch harness Transmission harness

9. TRANSFER Transfer type Number of transfer clutch drives & driven plates Control method Reduction gear ratio

Multi-plate transfer (MP-T) 6 Electronic hydraulic type 1.000 (37/37)

10.REDUCTION GEAR RATIO Model Front final reduction gear ratio

Except for OUTBACK 3.700

OUTBACK 3.900

11.RECOMMENDED GEAR OIL

( C) ( F)

(1) (2) (3) GL-5 (4) -30 -26 -15 -5 0 -22 -15 5 23 32

15 59

25 30 77 86 90

Lubrication oil

85W 80W 75W -90 MT-00001

(1) Item (2) Front differential gear oil Front differential oil capacity

2 (US qt, Imp qt)

(3) API standard (4) SAE viscosity No. and applicable temperature

1.3 — 1.5 (1.4 — 1.6, 1.1 — 1.3)

CVT-4

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

B: COMPONENT 1. TORQUE CONVERTER ASSEMBLY AND CONVERTER CASE (6)

(28) (10) T2 (5) (4)

(11) (12)

T6

T1

(17)

(14)

T7

T6

(16) (15)

T4

(18)

(20) (19)

(9)

(22)

(8)

T9

T3

(7)

(1)

(21)

(13)

(26)

(23)

(27)

T5

T8 (24) (25) (2)

(3)

T4

AT-05659

CVT-5

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General Description CONTINUOUSLY VARIABLE TRANSMISSION (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

Drive plate Reinforcement drive plate Torque converter ASSY O-ring Oil charge pipe cap Air breather hose ASSY O-ring O-ring PLUG Transmission harness stay Plug O-ring

(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25)

Oil stopper plate O-ring Lubrication pipe O-ring Lubrication pipe O-ring Stud bolt Transmission hanger Clip Straight pin Overflow drain plug Front differential gear oil drain plug

(13)

Converter case

(26)

Gasket

(27) (28)

Gasket Transmission radio ground cord

Tightening torque:N·m (kgf-m, ft-lb) T1: 9 (0.9, 6.6) T2: 16 (1.6, 11.8) T3: 18 (1.8, 13.3) T4: 25 (2.5, 18.4) T5: 35 (3.6, 25.8) T6: 41 (4.2, 30.2) T7: 50 (5.1, 36.9) T8: 70 (7.1, 51.6) T9:

CVT-6

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

2. OIL PUMP ASSY (9)

(7) (6) (5) (4) (3) (2)

T2

(8) (12)

(1)

T2 (11)

(13)

(10)

T1

AT-05108

(1) (2) (3) (4) (5) (6)

Oil seal Oil pump chain cover Snap ring Ball bearing Drive sprocket Oil pump chain

(7) (8) (9) (10) (11) (12)

Snap ring Driven sprocket Converter case Oil pump ASSY O-ring (large) O-ring (small)

CVT-7

(13)

Drive pinion retainer

Tightening torque:N·m (kgf-m, ft-lb) T1: 8.5 (0.9, 6.3) T2: 24 (2.4, 17.7)

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

3. TRANSMISSION CASE

T1 (6)

T3

(13) (5) (8) (9)

(6)

T4

(5)

(7) (10)

(4) (2)

(3)

(8)

(11)

(1) (12) (13) (19) (20)

T1 (15) (14)

T3

T2 (16) (17) (18)

AT-05109

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Snap ring Roller bearing Seal ring Oil seal O-ring PLUG PLUG O-ring Straight pin

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Seal ring Ball bearing O-ring Plug Plug O-ring Transmission case Roller bearing Snap ring

CVT-8

(19) (20)

Lubrication pipe O-ring

Tightening torque:N·m (kgf-m, ft-lb) T1: 13 (1.3, 9.6) T2: 16 (1.6, 11.8) T3: 25 (2.5, 18.4) T4: 35 (3.6, 25.8)

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

4. CONTROL VALVE BODY

T4

(3) (2)

(1)

(6) (4)

(7)

(5)

(8)

(4)

(9)

T2

(10) (11)

(12)

T2

(13)

T1 (14) (15)

T3 AT-05110

(1) (2) (3) (4) (5) (6) (7)

Transmission case Gasket Filler plug O-ring Pressure pipe O-ring (small) CVTF pipe

(8) (9) (10) (11) (12) (13) (14)

O-ring (large) Control valve body O-ring Oil strainer Magnet Oil pan Gasket

CVT-9

(15)

CVTF drain plug

Tightening torque:N·m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 9 (0.9, 6.6) T3: 20 (2.0, 14.8) T4: 50 (5.1, 36.9)

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

5. REVERSE BRAKE ASSEMBLY AND INTERMEDIATE CASE (1)

(2)

(7)

(5)

(4) (3)

(13)

(6)

(12)

(11)

T (10) (9) (16)

(8)

(15)

T

(14) AT-05111

(1) (2) (3) (4) (5) (6) (7)

Transmission case O-ring Snap ring Retaining plate Drive plate Driven plate Dish plate

(8) (9) (10) (11) (12) (13)

Snap ring Spring retainer Return spring Reverse brake piston Intermediate case Straight pin

CVT-10

(14) (15) (16)

CVTF filter PLUG O-ring

Tightening torque:N·m (kgf-m, ft-lb) T: 25 (2.5, 18.4)

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

6. FORWARD CLUTCH ASSEMBLY AND REDUCTION DRIVEN GEAR (1) (5)

(6) (4) (3) (2)

(15)

(17) (16)

(14) (25)

(12)

(13)

(11) (10) (22) (9)

(24)

(8)

(7)

(23)

(21)

(22)

(20)

(19) (18)

AT-05497

CVT-11

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General Description CONTINUOUSLY VARIABLE TRANSMISSION (1) (2)

Transmission case Reduction driven gear

(10) (11)

Return spring Forward clutch piston retainer

(19) (20)

Washer Sun gear ASSY

(3) (4) (5) (6) (7) (8) (9)

Ball bearing Reduction driven gear retainer Straight pin Snap ring Washer Forward clutch drum Forward clutch piston

(12) (13) (14) (15) (16) (17) (18)

Snap ring Dish plate Driven plate Drive plate Retaining plate Snap ring Thrust needle bearing

(21) (22) (23) (24) (25)

Internal gear Thrust needle bearing Snap ring Planetary carrier ASSY Intermediate case

CVT-12

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

7. FRONT REDUCTION DRIVE GEAR AND FRONT REDUCTION DRIVEN GEAR

(8)

(9)

(7) (11)

(10) (5)

(21) (4) (3) (6) (2) (1)

(24)

(20)

(19)

(23)

(18)

T3

(17)

(25)

T2

(16) (13)

(15) (14)

T1 T2 (22) (12)

AT-05112

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Shim Ball bearing Front reduction driven gear Dish plate Driven plate Drive plate Retaining plate Snap ring Seal ring Front reduction driven shaft

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)

Ball bearing Oil pump chain cover Seal ring Center support COMPL Converter case cover Shim O-ring Seal ring Ball bearing Front reduction drive gear

CVT-13

(21) (22) (23) (24) (25)

Ball bearing O-ring Converter case Seal ring O-ring

Tightening torque:N·m (kgf-m, ft-lb) T1: 21.5 (2.2, 15.9) T2: 24 (2.4, 17.7) T3: 25 (2.5, 18.4)

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

8. TRANSMISSION CONTROL DEVICE

T3

(5)

(2)

(13)

(1) (12) (4)

(11)

T1 T3 (3)

(10)

(8)

T2

(7)

(9)

T2

(6)

AT-05113

(1) (2) (3) (4) (5) (6) (7)

Spring pin Shifter arm Inhibitor switch Shifter arm shaft Plate ASSY Spring pin Manual plate

(8) (9) (10) (11) (12) (13)

Parking rod Detent spring Parking support Return spring Parking pawl Shaft

CVT-14

Tightening torque:N·m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 7 (0.7, 5.2) T3: 25 (2.5, 18.4)

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

9. PRIMARY PULLEY, SECONDARY PULLEY AND VARIATOR CHAIN

(7) (9) (8)

(6)

(10) (5)

T1

(2)

(11)

T3

(3) (4) (4)

T2 (7) (12) (13)

(14) (1) AT-05114

(1) (2) (3) (4) (5) (6) (7)

Converter case Seal washer Shim Seal ring Primary pulley ASSY Variator chain Chain guide

(8) (9) (10) (11) (12) (13) (14)

Lubrication pipe O-ring Support rod Secondary pulley ASSY PLUG O-ring Drive pinion retainer

CVT-15

Tightening torque:N·m (kgf-m, ft-lb) T1: 21 (2.1, 15.5) T2: 25 (2.5, 18.4) T3: 33 (3.4, 24.3)

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

10.FRONT DIFFERENTIAL GEAR T2

(18) (20)

(19)

(19)

(15)

(17)

T5

T2

(14) T4

(17) (16)

(6) (11)

(12) (13) (12) (11)

(13)

(5) T1 (6) (8)

T3

(9) (10)

(1) (2) (3)

(5)

(7)

(4)

(1)

T1 (4) (3) (2)

CVT-16

AT-05115

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General Description CONTINUOUSLY VARIABLE TRANSMISSION (1) (2) (3) (4) (5) (6) (7) (8) (9)

Lock plate Oil seal Differential side retainer O-ring Taper roller bearing Drive pinion gear set Pinion shaft Differential case RH Straight pin

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Differential case LH Washer Differential bevel gear Differential bevel pinion Taper roller bearing Shim Lock nut Oil seal Drive pinion retainer

CVT-17

(19) (20)

O-ring Lubrication pipe

Tightening torque:N·m (kgf-m, ft-lb) T1: 25 (2.5, 18.4) T2: 43 (4.4, 31.7) T3: 69 (7.0, 50.9) T4: 70 (7.1, 51.6) T5: 130 (13.3, 95.9)

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

11.TRANSFER AND EXTENSION CASE (7)

(8)

(6)

(5)

(4) (3) (2) (1)

(12) (11)

(21)

(10)

(20)

(9)

(19)

(18)

(17) (15) (13)

(16) (18)

(14)

(25) (23)

(24)

(22)

T

AT-05116

CVT-18

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General Description CONTINUOUSLY VARIABLE TRANSMISSION (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Seal ring Ball bearing Transfer drive gear Parking gear Snap ring Reduction drive gear shaft Thrust needle bearing Needle bearing Ball bearing Transfer reduction driven gear

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)

Ball bearing Shim Transfer piston Return spring Transfer piston seal Snap ring Pressure plate Transfer clutch plate set Snap ring Rear drive shaft

CVT-19

(21) (22) (23) (24) (25)

Ball bearing Extension case Transmission hanger Oil seal Dust cover

Tightening torque:N·m (kgf-m, ft-lb) T: 25 (2.5, 18.4)

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

12.TRANSMISSION HARNESS AND SENSOR (1)

T2

T2

(3) (2)

T2

T1

T4

(6)

T3 T1

(7)

(8)

(4) (5)

(9)

(10)

(11)

T1 (12)

AT-05512

(1) (2) (3) (4) (5) (6)

Transmission cover Transmission harness Inhibitor harness Secondary pressure sensor O-ring Primary speed sensor

(7) (8) (9) (10) (11) (12)

O-ring O-ring O-ring Secondary speed sensor O-ring Front wheel speed sensor

CVT-20

Tightening torque:N·m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 8 (0.8, 5.9) T3: 16 (1.6, 11.8) T4: 39 (4.0, 28.8)

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

13.CVTF COOLER PIPE AND HOSE

(10)

T3 (10)

T3

(9)

(1)

(7)

T1

(2)

(8)

T2

(6)

T1 B

(2)

(5)

T1

A B

(2) (2)

A

(3)

(2)

T1

(14)

(4)

T1 (2)

(2) (11)

(13) (2) (2) (12)

AT-05613

CVT-21

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General Description CONTINUOUSLY VARIABLE TRANSMISSION (1) (2) (3) (4)

Radiator Clip Outlet hose Inlet hose

(8) (9) (10) (11)

CVTF outlet pipe CVTF inlet pipe Gasket CVTF cooler pipe ASSY (OUTBACK model)

(5)

CVTF cooler pipe ASSY (except for OUTBACK) CVTF outlet hose CVTF inlet hose

(12)

Outlet hose (OUTBACK model)

(13) (14)

Inlet hose (OUTBACK model) CVTF oil cooler (OUTBACK model)

(6) (7)

Tightening torque:N·m (kgf-m, ft-lb) T1: 7.5 (0.76, 5.5) T2: 16 (1.6, 11.8) T3: 40 (4.1, 29.5)

14.TRANSMISSION CONTROL MODULE

T

(1)

(2)

AT-05602

(1)

Transmission control module (TCM)

(2)

Tightening torque:N·m (kgf-m, ft-lb)

Relay

T: 7.5 (0.75, 5.5)

CVT-22

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

15.TRANSMISSION MOUNTING

(4)

T2

T2

(5)

T1

T4

T3 T4

(3) T4

(6)

T1

T4

(1)

T1

T3

(3)

(2) T4

AT-05603

(1) (2) (3)

Tightening torque:N·m (kgf-m, ft-lb)

Transmission mounting bracket (RH) Transmission mounting bracket (LH)

(4)

Rear cushion rubber

(5)

Transmission rear crossmember

T1: 35 (3.6, 25.8)

Collar

(6)

Stopper

T2: 40 (4.1, 33.2) T3: 45 (4.6, 51.6) T4: 75 (7.6, 55.3)

CVT-23

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General Description CONTINUOUSLY VARIABLE TRANSMISSION

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Do not place the oil pan with its inner side facing up until it is installed, to prevent intrusion of foreign matter into the control valve body. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry apart with screwdrivers or other tools. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Use SUBARU genuine CVTF and recommended grease. Do not mix CVTF, grease etc. of different grades or manufacturers. • Be sure to tighten bolts and nuts to the specified torque. • Place lifts, shop jacks or rigid racks at specified locations. • Apply CVTF onto sliding or revolving surfaces before installation. • Replace deformed or damaged snap rings with new parts. • Before installing O-rings or oil seals, apply sufficient amount of CVTF to avoid damage and deformation. • Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts. • Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. • Avoid damaging the mating surface of the case. • Before applying liquid gasket, completely remove the old liquid gasket. • After removing the sensors, breather hose and plugs, plug the holes to avoid foreign materials intruding as necessary.

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER DESCRIPTION 18801AA000 OIL PRESSURE (Newly adopted tool) GAUGE ASSY

REMARKS Used for measuring the secondary hydraulic pressure (line pressure).

18658AA020 WRENCH COMPL (Newly adopted tool) RETAINER

Used for removing and installing the differential side retainer.

ST18801AA000

ST18658AA020

CVT-24

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General Description CONTINUOUSLY VARIABLE TRANSMISSION ILLUSTRATION

TOOL NUMBER DESCRIPTION 18681AA000 PRESSURE (Newly adopted tool) GAUGE ADAPTER

REMARKS Used for measuring oil pressure. NOTE: Used together with the genuine O-ring (part No. 806911080).

41099AJ000 FRONT MOUNT(Newly adopted tool) ING H4

Used for holding and balancing the engine unit.

18769AA000 EXPANDER (Newly adopted tool) PULLER

Used for removing and installing the secondary pulley assembly.

ST18681AA000

ST41099AJ000

ST18769AA000

10004AA180 (SUBARU genuine part)

ENGINE HANGER REAR

Used for removing and installing the automatic transmission assembly. (ENGINE HANGER REAR for turbo model)

ST10004AA180

99099AJ000 ENGINE HANGER (Newly adopted tool)

ST99099AJ000

CVT-25

• Used for removing and installing the automatic transmission assembly. • Used together with CHAIN BALANCER (99099AJ010).

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General Description CONTINUOUSLY VARIABLE TRANSMISSION ILLUSTRATION

TOOL NUMBER DESCRIPTION 99099AJ010 CHAIN BALANCER (Newly adopted tool)

REMARKS • Used for removing and installing the automatic transmission assembly. • Used together with ENGINE HANGER (99099AJ000).

ST99099AJ010

498897700

OIL PRESSURE ADAPTER SET

Used for measuring the secondary pressure (line pressure) and transfer clutch hydraulic pressure.

498575400

OIL PRESSURE GAUGE ASSY

Used for measuring the transfer clutch hydraulic pressure.

498277200

STOPPER SET

• Used for removing and installing automatic transmission assembly to engine. • Used for preventing the torque converter from dropping off.

398527700

PULLER ASSY

• Used for removing the extension case oil seal. • Used for removing the roller bearing of the primary pulley and secondary pulley. • Used for removing the bearing of reduction driven gear. • Used for removing the differential side retainer bearing outer race.

ST-498897700

ST-498575400

ST-498277200

ST-398527700

CVT-26

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General Description CONTINUOUSLY VARIABLE TRANSMISSION ILLUSTRATION

TOOL NUMBER 498057300

DESCRIPTION INSTALLER

REMARKS Used for installing the extension case oil seal.

18632AA000

TRANSMISSION STAND

Used for disassembling and assembling the transmission.

498255400

PLATE

Used for measuring the backlash of hypoid gear.

498247001

MAGNET BASE

• Used for measuring the backlash of hypoid gear. • Used together with DIAL GAUGE (498247100).

498247100

DIAL GAUGE

• Used for measuring the backlash of hypoid gear. • Used together with DIAL GAUGE (498247101).

ST-498057300

ST18632AA000

ST-498255400

ST-498247001

ST-498247100

CVT-27

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General Description CONTINUOUSLY VARIABLE TRANSMISSION ILLUSTRATION

TOOL NUMBER 18675AA000

DESCRIPTION DIFFERENTIAL SIDE OIL SEAL INSTALLER

REMARKS Used for installing the differential side retainer oil seal.

18762AA000

COMPRESSOR SPECIAL TOOL

Used for disassembling multi-plate clutch for shift transmission.

18765AA000

COMPRESSOR SUPPORT

Used for disassembling multi-plate clutch for shift transmission.

18763AA000

COMPRESSOR SHAFT

Used for disassembling multi-plate clutch for shift transmission.

28399SA010

OIL SEAL PROTEC- Used for protecting oil seal when installing front TOR drive shaft.

ST18675AA000

ST18762AA000

ST18765AA000

ST18763AA000

ST28399SA010

CVT-28

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General Description CONTINUOUSLY VARIABLE TRANSMISSION ILLUSTRATION

TOOL NUMBER 18667AA010

DESCRIPTION HOLDER

REMARKS • Used for removing and installing the drive pinion lock nut. • Used as a handle to rotate gear when checking tooth contact.

SOCKET (E20)

• Used for removing and installing the hypoid driven gear. • Used for removing and installing the drive pinion shaft retainer.

398497701

SEAT

Used for removing and installing the ball bearing.

398177700

INSTALLER

Used for removing and installing the ball bearing and tapered roller bearing.

398643600

GAUGE

Used for measuring the total end play, extension end play and drive pinion height.

ST18667AA010

18270KA020

ST18270KA020

ST-398497701

ST-398177700

ST-398643600

CVT-29

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General Description CONTINUOUSLY VARIABLE TRANSMISSION ILLUSTRATION

TOOL NUMBER 899864100

DESCRIPTION REMOVER

REMARKS Used for removing and installing the ball bearing.

498077000

REMOVER

Used for removing the differential taper roller bearing.

18657AA010

INSTALLER

Used for installing the oil seal of inhibitor switch.

18621AA000

ADAPTER WRENCH

Used for removing and installing the drive pinion shaft lock nut.

18651AA000

INSTALLER

Used for installing the differential taper roller bearing.

ST-899864100

ST-498077000

ST18657AA010

ST18621AA000

ST18651AA000

CVT-30

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General Description CONTINUOUSLY VARIABLE TRANSMISSION ILLUSTRATION

TOOL NUMBER 18720AA000

DESCRIPTION REMOVER

REMARKS Used for removing ball bearing of reduction driven gear.

18854AA000

ANGLE GAUGE

Used for installing the drive plate.

20299AG010

PRESS SNAP RING Used for installing the bearing of reduction driven gear.

ST18720AA000

ST18854AA000

ST20299AG010

398791600

REMOVER

Used for removing and installing the shifter arm spring pin.

399513600

INSTALLER

Used for removing the bearing of the oil pump chain sprocket.

ST-398791600

ST-399513600

CVT-31

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General Description CONTINUOUSLY VARIABLE TRANSMISSION ILLUSTRATION

TOOL NUMBER 499267300

DESCRIPTION STOPPER PIN

REMARKS Used for adjusting the inhibitor switch.

499277100

BUSHING 1-2 INSTALLER

Used for removing the transfer reduction driven gear.

499277200

INSTALLER

Used for removing the transfer reduction driven gear.

499575400

GAUGE

Used for measuring height of end play.

499737100

PULLER SET

• Used for measuring the transfer end play. • Use the rack only.

ST-499267300

ST-499277100

ST-499277200

ST-499575400

ST-499737100

CVT-32

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General Description CONTINUOUSLY VARIABLE TRANSMISSION ILLUSTRATION

TOOL NUMBER 499575600

DESCRIPTION GAUGE

REMARKS Used for measuring height of end play.

499787700

WRENCH

Used for measuring the differential pinion shaft backlash.

499757002

INSTALLER

Used for removing the transfer reduction driven gear.

18767AA000

REMOVER

Used for removing the transfer reduction driven gear.

ST-499575600

ST-499787700

ST-499757002

ST18767AA000

499755602

PRESS SNAP RING Used for installing the ball bearing, roller bearing and oil seal.

ST-499755602

CVT-33

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General Description CONTINUOUSLY VARIABLE TRANSMISSION ILLUSTRATION

TOOL NUMBER 498077600

DESCRIPTION REMOVER

REMARKS Used for removing the ball bearing of the rear drive shaft.

1B022XU0

SUBARU SELECT MONITOR III KIT

Used for troubleshooting the electrical system.

ST-498077600

ST1B022XU0

2. GENERAL TOOL TOOL NAME Circuit tester Thickness gauge Caliper Spring scale TORX® bit T70 TORX® bit E16 Straight pin remover Deep socket Push/pull gauge

Chain sling

Screw shackle

REMARKS Used for measuring resistance and voltage. Used for the clearance in reverse brake, forward clutch, transfer clutch and input clutch. Used for measuring the clearance at the parts. Used for measuring the starting torque of the drive pinion. Used for removing and installing differential gear oil drain plug. Used for removing and installing the center support COMPL. Used for removing and installing transmission gear oil drain plug. Used for removing and installing the secondary pressure sensor. NOTE: Use Ko-ken 3/8 12-point 27 mm (manufacturer product No. 3305M-27). Used for measuring clutch clearance. Used for removing and installing transmission. • Length: 0.8 — 1 m (2.6 — 3.3 ft) • Load capacity: 1.2 t (2646 lb) or more • Diameter: 6 mm (0.24 in) or 6.3 mm (0.25 in) • Chain external width: 23.5 mm (0.93 in) or less • Chain internal width: 8.5 mm (0.33 in) or more Used for removing and installing transmission. • Load capacity: 250 kg (551 lb) or more • Use two pieces.

CVT-34

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CVTF CONTINUOUSLY VARIABLE TRANSMISSION

2. CVTF A: INSPECTION Check for leakage of CVTF from transmission.

B: ADJUSTMENT CAUTION: • CVTF level changes along with CVTF temperature. When inspecting CVTF level, observe the specified CVTF temperature. • Always use specified CVTF or equivalent. Using other fluid except for specified or equivalent will cause malfunction. 1) Idle the engine to raise CVTF temperature to 35 — 45°C (95 — 113°F) on Subaru Select Monitor. 2) Set the vehicle on a lift. 3) Operate the select lever in P → R → N → D and D → N → R → P to circulate CVTF with the engine idling. 4) With the engine running, lift up the vehicle and remove the filler plug. CAUTION: Pay special attention to the following operations as the engine is at idle. NOTE: CVTF is at the specified level when it is up to the filler plug hole lower section.

(A)

AT-05119

(A) Filler plug

CVT-35

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CVTF CONTINUOUSLY VARIABLE TRANSMISSION

5) When there is no CVTF leakage from the transmission, add the specified fluid or equivalent up to the filler plug hole lower section.

CVT fluid:

CAUTION: Note that when CVTF is added up to the lower section of filler plug while the transmission is in cold condition, overfilling of CVTF occurs, causing the oil to spill out.

(A)

(A)

AT-05120

(A) Filler plug hole

6) Install the filler plug. NOTE: Use a new gasket.

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

CVT-36

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CVTF CONTINUOUSLY VARIABLE TRANSMISSION

C: REPLACEMENT CAUTION: • Directly after the vehicle has been running or the engine has been long idle running, the CVTF is hot. Be careful not to burn yourself. • Be careful not to spill the CVTF on exhaust pipe to prevent it from emitting smoke or causing fires. If CVTF adheres, wipe it off completely. • Always use specified CVTF or equivalent. Using other fluid except for specified or equivalent will cause malfunction. 1) Set the vehicle on a lift. 2) Lift up the vehicle, and remove the CVTF drain plug.

(A)

AT-05121

(A) CVTF drain plug

3) Check the CVTF condition. 4) Install the CVTF drain plug and gasket. NOTE: • Use a new gasket.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb)

CVT-37

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CVTF CONTINUOUSLY VARIABLE TRANSMISSION

5) Remove the filler plug.

(A)

AT-05119

(A) Filler plug

6) Fill in the specified fluid or equivalent through the filler plug.

CVT fluid:

Capacity: Fill with the same amount of CVTF as drained. 7) Temporarily tighten the filler plug. 8) Idle the engine to raise CVTF temperature to 35 — 45°C (95 — 113°F) on Subaru Select Monitor. 9) Operate the select lever in P → R → N → D and D → N → R → P to circulate CVTF with the engine idling. CAUTION: Pay special attention to the following operations as the engine is at idle. 10) Place the select lever in “P” range. Then lift up the vehicle with the engine at idle to adjust the CVTF level and check for leakage.

CVT-38

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CVTF CONTINUOUSLY VARIABLE TRANSMISSION

11) Replace with a new gasket, and attach the filler plug.

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

(A)

AT-05119

(A) Filler plug

D: CONDITION CHECK NOTE: When replacing CVTF, determine the condition inside the transmission body by inspecting the drained CVTF. Fluid condition Metal particles. Thick and varnish-form fluid.

Trouble and possible cause Excessive wear of the internal of the transmission body. Burnt clutches

Clouded CVTF or bubbles.

Water mixed in fluid.

CVT-39

Corrective action Replace CVTF and check if CVT operates correctly. Replace CVTF and check the CVT body or vehicle for faulty. Replace CVTF and check the water entering point.

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Differential Gear Oil CONTINUOUSLY VARIABLE TRANSMISSION

3. Differential Gear Oil A: ADJUSTMENT NOTE: Immediately after removing the overflow drain plug, remaining gear oil (approx. 8 cc) may come out of the overflow pipe. This is not included in the specified amount. When removing the overflow drain plug, make sure the gear oil flows out of the overflow drain plug hole by filling with gear oil. 1) Remove the air breather cap.

AT-05126

2) Lift up the vehicle. 3) Remove the overflow drain plug.

(A) AT-05125

(A) Overflow drain plug

4) Fill in the differential gear oil through the charge pipe up to where the oil flows out of the overflow drain plug.

Recommended gear oil:

CVT-40

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Differential Gear Oil CONTINUOUSLY VARIABLE TRANSMISSION

5) When the flow of the differential gear oil turns into a narrow stream, install the overflow drain plug. NOTE: Use a new gasket.

Tightening torque: 35 N·m (3.6 kgf-m, 25.8 ft-lb)

AT-05597

CVT-41

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Differential Gear Oil CONTINUOUSLY VARIABLE TRANSMISSION

B: REPLACEMENT CAUTION: • Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself. • Be careful not to spill differential gear oil on the exhaust pipe to prevent it from emitting smoke or causing a fire. If gear oil adheres, wipe it off completely. 1) Lift up the vehicle. 2) Remove the differential gear oil drain plug using TORX® bit T70. Drain differential gear oil. 3) Install the differential gear oil drain plug using TORX® bit T70. NOTE: Use a new gasket.

Tightening torque: 70 N·m (7.1 kgf-m, 51.6 ft-lb)

(A)

AT-05127

(A) Differential gear oil drain plug

CVT-42

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Differential Gear Oil CONTINUOUSLY VARIABLE TRANSMISSION

4) Pour gear oil from the charge pipe.

Recommended gear oil:

Gear oil capacity:

AT-05598

5) Adjust the level of differential gear oil.

CVT-43

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Variator Chain Break-in CONTINUOUSLY VARIABLE TRANSMISSION

4. Variator Chain Break-in A: GENERAL DESCRIPTION Perform Variator Chain Break-in when the following work has been performed. • Variator chain replacement • Primary pulley and secondary pulley replacement

B: PROCEDURE NOTE: • During variator chain break-in, VDC warning light and EPB warning light illuminate because of the difference between the vehicle speed value and G sensor value. This is not the malfunction. If the warning light illuminates, clear the VDC and EPB memory after the variator chain break-in is finished. • During variator chain break-in, if the above malfunction code is detected, fail mode is entered. If this happens, symptom such as engine speed rapid increase occurs, even when the accelerator pedal is depressed gradually. 1) Lift up the vehicle. CAUTION: Lift up the vehicle until the tire bottom is 0.3 m (0.98 ft) or more above the ground. 2) Shift the select lever from “P” to “N” range. 3) Apply the electronic parking brake. 4) Connect the Subaru Select Monitor to data link connector. 5) Idle the engine to raise CVTF temperature to 40 — 50°C (104 — 122°F) on Subaru Select Monitor. NOTE: When CVTF temperature does not rise easily or if you want to rise CVTF temperature faster, maintain the engine speed within 2,000 - 2,500 rpm at “P” or “N” range to raise the CVTF temperature. 6) With the select lever in “P” or “N” range, increase the engine speed to 3,000 - 3,500 rpm from the idling condition, and maintain approximately five seconds, then release the accelerator pedal. 7) Depress the accelerator pedal gradually again from idling condition to increase the engine speed to 3,000 - 3,500 rpm, and maintain approximately five seconds, then release the accelerator pedal. 8) Release the electronic parking brake. 9) Shift the select lever into manual mode to set the 1st. 10) Depress the accelerator pedal gradually, and increase the engine speed to 5,300 rpm from engine idling condition. NOTE: Increase the engine speed while observing it, so as not to overspeed the engine. 11) Return the accelerator pedal to fully closed position to lower the engine speed to 4,000 rpm. 12) Depress the accelerator pedal gradually again, and increase the engine speed to 5,300 rpm. 13) Repeat the step 11) and 12) for 40 times. 14) Return the accelerator pedal to return the engine idling speed. 15) Shift the select lever to “P” range, and then turn the engine to OFF.

CVT-44

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AWD ON/OFF Switching Mode CONTINUOUSLY VARIABLE TRANSMISSION

5. AWD ON/OFF Switching Mode A: GENERAL DESCRIPTION • Follow the messages displayed on the Subaru Select Monitor when working. • Perform as necessary in FWD mode. • When switched to FWD, AWD light illuminates.

B: PROCEDURE CAUTION: • Do not turn the power of the Subaru Select Monitor OFF during work, and do not disconnect the data link connector. • On completing the work in FWD, switch back in AWD. 1) Shift the select lever to “P” range. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON. (In the case of a push button start, press the push button ignition switch twice without stepping on the brake) 4) Turn off all switches causing an electrical load, such as headlights, A/C, seat heater and rear defogger. 5) Select {AT related learning & inspecting mode} in the «Transmission Diagnosis» screen of the Subaru Select Monitor. 6) Select {AWD ON/OFF switching mode} in the «Learning and inspection mode related to AT» display screen of the Subaru Select Monitor. 7) Follow the messages displayed on the Subaru Select Monitor screen when working. Switching completes successfully if any of the following messages is displayed. • When switching from AWD to FWD: {Switched to FF. To return to AWD, perform basic mode again.} • When switching from FWD to AWD: {Switched to AWD. To return to FF, perform basic mode again.} NOTE: • If communication error occurs during switching mode, start in the “AWD ON/OFF switching mode” again. • If operation is interrupted before the successful end message is displayed, perform the {AWD ON/OFF switching mode} from the beginning until confirming the operation is successfully ended. If this mode fails to complete successfully, the cause is as follows. • Select lever is not in “P” range. • Engine is running. • For details concerning the operation procedure, refer to “PC application help for Subaru Select Monitor”.

CVT-45

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Road Test CONTINUOUSLY VARIABLE TRANSMISSION

6. Road Test A: INSPECTION 1. GENERAL PRECAUTION Road tests should be conducted to properly diagnose the condition of CVT. CAUTION: Always observe the local traffic laws when performing the test.

2. D RANGE SHIFT FUNCTION Make sure the engine speed is 1,100 — 1,300 rpm while driving on the level road at 50 km/h (31 MPH) after accelerating from halting to 1/4 of accelerator opening angle. Then stop the vehicle. Check normal gear change has occurred while the vehicle speed changes from a constant speed to zero.

3. KICK-DOWN FUNCTION Check if engine speed will rise by operating the accelerator opening angle to the full from a constant speed of 50 km/h (31 MPH) or more.

4. ENGINE BRAKE OPERATION • Drive in “6th speed of manual mode” [70 — 80 km/h (43 — 50 MPH)], and shift down from 6th to 5th. Check if the indicator of combination meter switches “6” → “5”. At the same time, check the engine brake in 5th gear. • Drive in “5th speed of manual mode” [60 — 70 km/h (37 — 43 MPH)], and shift down from 5th to 4th. Check if the indicator of combination meter switches “5” → “4”. At the same time, check the engine brake in 4th gear. • Drive in “4th speed of manual mode” [50 — 60 km/h (31 — 37 MPH)], and shift down from 4th to 3rd. Check if the indicator of combination meter switches “4” → “3”. At the same time, check the engine brake in 3rd gear. • Drive in “3rd speed of manual mode” [40 — 50 km/h (25 — 31 MPH)], and shift down from 3rd to 2nd. Check if the indicator of combination meter switches “3” → “2”. At the same time, check the engine brake in 2nd gear. • Drive in “2nd speed of manual mode” [20 — 30 km/h (12 — 19 MPH)], and shift down from 2nd to 1st. Check if the indicator of combination meter switches “2” → “1”. At the same time, check the engine brake in 1st gear.

5. LOCK-UP FUNCTION When the accelerator is lightly depressed while driving on a flat road in “D” range, check that rpm does not change abruptly.

6. P RANGE OPERATION Stop the vehicle on an uphill grade of 5% or more and shift to the “P” range and apply the parking brake. Check that the vehicle does not move when the parking brake is released.

7. NOISE AND VIBRATION Check for noise and vibration during a constant driving, accelerating, decelerating and manual shift operation.

8. OIL LEAKAGE After the driving test, inspect for leakage of CVTF and differential gear oil from the transmission body.

CVT-46

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Stall Test CONTINUOUSLY VARIABLE TRANSMISSION

7. Stall Test A: INSPECTION CAUTION: Make sure no other person is around the vehicle during stall test measurement. NOTE: Stall test is extremely important in diagnosing the condition of CVT and engine. The test is necessary to measure the engine stall speeds in “R” and “D” range. Purposes of the stall test: • Operational check of forward clutch and reverse brake • Operational check of the torque converter assembly • Engine performance check 1) Place wheel chocks at the front and rear of all wheels and engage the electronic parking brake. 2) Turn the A/C OFF. 3) Using the Subaru Select Monitor, check if the throttle valve operates when you depress the accelerator pedal. 4) Check the engine oil level. 5) Check the coolant level. 6) Adjust the CVTF level. 7) Increase the CVT temperature to 60 to 80°C (140 to 176°F) by idling the engine (with select lever set to “N” or “P” range). 8) Shift the select lever to “D” range. 9) Depress the accelerator pedal to the full while fully depressing the foot brake pedal with your left foot. 10) When the engine speed stabilizes, quickly record the engine speed and release accelerator pedal. Shift the select lever to “N” range. Let the engine idle for one minute or more to cool it down. 11) Shift to “R” range and perform the same stall test. NOTE: • Do not perform a stall test for over 5 seconds at a time. (from closed throttle, fully open throttle to stall speed reading.) Failure to follow this instruction will cause the engine oil and CVTF to deteriorate and the clutch and brake to be adversely affected. • Be sure to cool down the engine for at least one minute after each stall test with the select lever set in the “P” or “N” range and with the idle speed of 1,200 rpm or less. • If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the CVT from sustaining damage.

Stall speed standard: 2,400 — 3,100 rpm Stall test judgment Range Lower than standard value

Range D, R

D

Higher than standard value

R

D, R

• • • • • • • • • • • • • • •

Probable cause Throttle valve is not fully open. Insufficient engine output Torque converter malfunction Forward clutch slippage Secondary pressure (line pressure) is low. Variator chain malfunction Input clutch slippage Reverse brake slippage Secondary pressure (line pressure) is low. Variator chain malfunction Input clutch slippage Torque converter malfunction Control valve body malfunction TCM malfunction Damaged harness and harness connector

CVT-47

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Time Lag Test CONTINUOUSLY VARIABLE TRANSMISSION

8. Time Lag Test A: INSPECTION NOTE: When the select lever is shifted while the engine is idling, there will be a certain time elapse or lag before shock is felt. This symptom helps to check the condition of forward clutch and reverse brake. • Perform the test at normal operation CVTF temperature of 60 — 80°C (140 — 176°F). • Be sure to allow one minute or more interval between tests. • Make three measurements and take the average value. 1) Apply the electronic parking brake. 2) Start the engine. Check the idling speed. (A/C OFF) 3) Shift the select lever from “N” to “D” range. Using a stop watch, measure the time elapsed from shifting the lever until the shock is felt.

Time lag standard: 1.2 seconds or less If “N” → “D” time lag is longer than specified: • Secondary pressure (line pressure) is too low. • Forward clutch worn • Piston malfunction • Control valve body malfunction • Learning incomplete 4) In the same manner, measure the time lag when shifting “N” → “R” range. Time lag standard: 1.5 seconds or less If “N” → “R” time lag is longer than specified: • Secondary pressure (line pressure) is too low. • Reverse brake worn • Piston malfunction • Control valve body malfunction • Learning incomplete

CVT-48

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Secondary Pressure (Line Pressure) Test CONTINUOUSLY VARIABLE TRANSMISSION

9. Secondary Pressure (Line Pressure) Test A: INSPECTION CAUTION: Make sure no other person is around the vehicle during secondary pressure (line pressure) test measurement. NOTE: • If the pulley and variator chain, clutch or brake show signs of slipping or shift feel is not correct, check the secondary pressure (line pressure). • Connect Subaru Select Monitor to vehicle so as to measure the engine speed and actual secondary pressure (secondary pressure (line pressure)). • In many cases, slippage or inability to operate the vehicle may be due to insufficient oil pressure for the operation of clutch, brake or control valve. 1) Remove the front wheel RH. 2) Lift up the vehicle. 3) Remove the plug for measuring secondary pressure (line pressure).

AT-05609

CVT-49

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Secondary Pressure (Line Pressure) Test CONTINUOUSLY VARIABLE TRANSMISSION

4) Attach ST1, ST2 and ST3 to transmission. ST1 18801AA000 OIL PRESSURE GAUGE ASSY ST2 18681AA000 PRESSURE GAUGE ADAPTER ST3 498897700 OIL PRESSURE ADAPTER SET NOTE: ST2 Used with genuine O-ring (part No. 806911080) attached to PRESSURE GAUGE ADAPTER.

ST3 ST1

ST2

(A)

AT-05123

(A) O-ring (genuine part)

5) Set the gauge so that it can be seen from the driver’s seat. 6) Install the front wheel RH. 7) Using the Subaru Select Monitor, check if the throttle valve operates when you depress the accelerator pedal. 8) Check the engine oil level. 9) Check the coolant level. 10) Adjust the CVTF level. 11) Increase the CVT temperature to 60 to 80°C (140 to 176°F) by idling the engine (with select lever shift to “N” or “P” range). 12) Shift the select lever to “D” range. 13) Depress the accelerator pedal to the full while fully depressing the foot brake pedal with your left foot.

CVT-50

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Secondary Pressure (Line Pressure) Test CONTINUOUSLY VARIABLE TRANSMISSION

14) Immediately after the engine speed becomes steady, record the reading of the secondary pressure (line pressure), engine speed and actual secondary pressure on Subaru Select Monitor. And then release the accelerator pedal. Shift the select lever to “N” range. Let the engine idle for one minute or more to cool it down. NOTE: • Do not continue the stall test for 5 seconds or more at a time (from fully closed throttle, fully open throttle to secondary pressure (line pressure) reading). Failure to follow this instruction will cause the engine oil and CVTF to deteriorate and the clutch and brake to be adversely affected. • After performing the secondary pressure (line pressure) test, be sure to cool down the engine for at least one minute with the select lever set in “P” or “N” range and with the idle speed at 1,200 rpm or less. • Under each condition, check that the measured pressure matches almost totally with actual secondary pressure. • When both measured pressure and actual secondary pressure are out of specification, judge as control valve malfunction. • The value at stall is for reference because the pressure changes under different conditions or circumstances. • The value at idling is steady because it is not affected by any condition or circumstance. Range Stall Idling

D, R P, N

Secondary pressure (line pressure) standard Secondary pressure (line pressure) Throttle Brake (MPa (kgf/cm2, psi)) Full open ON 5 — 6 (51.0 — 61.2, 725 — 870) Full closed OFF 0.5 — 1.5 (5.1 — 15.3, 72 — 218)

15) Remove the ST and install the plug after measurement. NOTE: Use new O-rings.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

CVT-51

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Transfer Clutch Pressure Test CONTINUOUSLY VARIABLE TRANSMISSION

10.Transfer Clutch Pressure Test A: INSPECTION 1) Lift up the vehicle. 2) Remove the test plug.

AT-05189

3) Set the ST1, ST2 and ST3 to transmission. ST1 498575400 OIL PRESSURE GAUGE ASSY ST2 498897700 OIL PRESSURE ADAPTER SET ST3 18681AA000 PRESSURE GAUGE ADAPTER NOTE: ST3 Used with genuine O-ring (part No. 806911080) attached to PRESSURE GAUGE ADAPTER.

(A)

ST3

ST1

ST2

AT-05124

(A) O-ring (genuine part)

4) Lower the vehicle. 5) Connect the Subaru Select Monitor to the data link connector and read the current data.

CVT-52

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Transfer Clutch Pressure Test CONTINUOUSLY VARIABLE TRANSMISSION

6) Check the transfer clutch pressure as in secondary pressure (line pressure) test. NOTE: • Use Subaru Select Monitor for switching to FWD mode. • If no oil pressure is produced, if it does not change in AWD mode or if oil pressure is produced in FWD mode, there may be a problem in the control valve body. Range position

ON Duty ratio (%)

Accelerator opening angle (%)

95 — 100

Fully opened (100)

60

Adjust ON Duty ratio to 60%.

0 0

Fully closed (0) Fully closed (0)

Manual mode (2nd)

N or P

7) Remove the ST and install the plug after measurement. NOTE: Use new O-rings.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

CVT-53

Standard transfer clutch pressure kPa (kg/cm2, psi) AWD mode

FWD mode

1,000 — 1,200 (10.2 — 12.2, 145 — 174)



400 — 700 (4.1 — 7.1, 58 — 102) — 0

— 0 (0, 0) —

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

11.Automatic Transmission Assembly A: REMOVAL 1) Set the vehicle on a lift. 2) Remove the front wheels. 3) Disconnect the ground cable from battery. 4) Remove the air intake duct. 5) Remove the air intake boot assembly. 6) Remove the ten clips and remove the grille bracket.

AT-05636

7) Disconnect the following connectors. • Transmission harness connectors • Transmission radio ground terminal

(A) (B)

AT-05128

(A) Transmission harness connectors (B) Transmission radio ground terminal

CVT-54

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

8) Separate the battery cable clip to remove the bracket.

AT-05611

9) Remove the starter. 10) Remove the throttle body. 11) Remove the manifold absolute pressure sensor. 12) Remove the bolt and disconnect the engine harness connector.

CS-01220

CVT-55

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

13) Remove the engine harness connector from the engine hanger rear.

CS-01221

14) Remove the engine hanger rear.

AT-05449

CVT-56

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

15) Remove the service hole plug.

AT-05131

16) Install the engine hanger rear for turbo model. Part No. 10004AA180 Engine hanger rear

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

AT-05450

CVT-57

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

17) Remove the four bolts combining the torque converter and drive plate while rotating the crank pulley a little at a time in the same direction as engine revolution. CAUTION: • Be careful not to drop bolts into converter housing. • Be careful not to damage the mounting bolts.

AT-05451

18) Make sure the torque converter moves freely by rotating with finger through the starter installation hole. 19) Attach the ST to the converter case. ST 498277200 Stopper set

AT-05132

CVT-58

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

20) After pulling off the cotter pin and removing the castle nut, use a puller to remove the tie-rod end from the knuckle arm.

(A)

(B)

(C) AT-05134

(A) Cotter pin (B) Tie-rod end (C) Castle nut

21) Lift up the vehicle. 22) Remove the under cover. 23) Remove the center exhaust pipe. 24) Remove the CVTF drain plug to drain CVTF. 25) Remove the heat shield cover.

CS-01104

CVT-59

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

26) Remove the snap pin and washer from shifter arm and remove the select cable from shifter arm.

(B)

(D)

(C) (A) AT-05631

(A) (B) (C) (D)

Shifter arm Snap pin Select cable Washer

27) Remove the plate assembly from the transmission case.

(A) (B) AT-05632

(A) Select cable (B) Plate ASSY

28) Drain differential gear oil.

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

29) Remove the CVTF inlet hose and CVTF outlet hose.

AT-05612

30) Remove the universal joint. 31) Remove the propeller shaft. 32) Remove the stabilizer link. 33) Disconnect the lower arm ball joint and housing. 34) Pull out the front drive shaft from transmission using a crowbar. 35) Holding the joint of front drive shaft from transmission side, pull out the drive shaft from transmission with care not to stretch the boot. 36) Lower the vehicle. 37) Remove the nuts from left and right transmission mounting brackets.

AT-05622

CVT-61

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

38) Set the ST1 and ST2 to vehicle. ST1 99099AJ000 ENGINE HANGER ST2 99099AJ010 CHAIN BALANCER CAUTION: • Set so that the chain sling does not hit the engine parts. • Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.

ST2

ST1

AT-05514

ST2

ST1

AT-05515

CVT-62

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

39) Remove the stopper rod.

CS-01155

40) Lift the engine slightly and remove the engine mounting bolts.

AT-05628

CVT-63

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

41) Remove the engine mounting nut and bolt to remove the engine mounting.

AT-05629

42) Temporarily install the ST by using two bolts. ST 41099AJ000 FRONT MOUNTING H4

ST

CS-01157

CVT-64

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

43) Lift up the engine unit high enough to install the bolt and nut to vehicle. CAUTION: Do not lift up higher than enough level to install the ST to avoid damage to the hoses and pipes inside the engine room. NOTE: • If it is difficult to pull out the stud bolt from transmission mounting bracket, shake the engine unit slightly while lifting up.

CS-01158

44) Tighten the attachment bolts at the engine side.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-05630

45) Remove the ST (ENGINE HANGER).

CVT-65

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

46) Remove the left and right transmission mounting brackets. NOTE: First, remove the transmission mounting bracket on the right side of vehicle, and then tilt the engine unit to remove the left transmission mounting bracket.

AT-05623

47) Remove the four transmission connecting bolts.

AT-05135

48) Set the ST (ENGINE HANGER) again to loosen the chain sling. 49) Lift up the vehicle. 50) Set the transmission jack under the transmission.

CVT-66

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

51) Remove the rear crossmember.

AT-05139

52) Lower the transmission rear end (dust cover rear end). CAUTION: When lowering the transmission rear end, be careful not to let the converter case and steering mechanical parts contact each other. NOTE: Lower the transmission rear end by approx. 80 mm (3.1 in) (reference).

AT-05138

53) Rotate the handle of ST (ENGINE HANGER) to apply tension to the chain sling.

CVT-67

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

54) Remove the two transmission connecting bolts and two nuts (lower side).

AT-05140

55) Remove the transmission assembly. NOTE: Remove it while moving the transmission jack up and down so that the engine and transmission remain directly aligned. 56) Remove the cushion rubber.

CVT-68

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

B: INSTALLATION 1) Attach the ST to converter case. ST 498277200 Stopper set

AT-05132

2) When completely overhauling the transmission, refill approx. 10 2 (2.6 US qt, 8.8 Imp qt) of CVTF through the transmission right side plug, and install the plug. CAUTION: Always use specified CVTF or equivalent. Using other fluid except for specified or equivalent will cause malfunction. NOTE: Use a new gasket.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-05141

CVT-69

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Replace the front differential side retainer oil seal. NOTE: Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is removed from the transmission. 4) Install the cushion rubber on the transmission.

Tightening torque: 40 N·m (4.1 kgf-m, 29.5 ft-lb) 5) Mount the transmission onto the transmission jack. 6) Strike and bend the transmission hanger of transmission rear with a soft rubber hammer etc. so that it gets in contact with the transmission case. CAUTION: Do not apply extra overload or impact to the transmission case.

AT-05596

7) While lifting up the transmission gradually, install the transmission to the engine. CAUTION: This operation requires at least two persons. NOTE: Keep the engine level.

CVT-70

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

8) Install the two engine connecting bolts and two nuts (lower side).

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

AT-05140

9) Secure the transmission rear crossmember to the vehicle body.

Tightening torque: T1: 35 N·m (3.6 kgf-m, 25.8 ft-lb) T2: 75 N·m (7.6 kgf-m, 55.3 ft-lb)

T2

T1

T2

AT-05143

10) Remove the transmission jack. 11) Lower the vehicle. 12) Remove the ST (ENGINE HANGER).

CVT-71

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

13) Install the four engine mounting bolts (upper side).

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

AT-05135

14) Install the left and right transmission mounting brackets. NOTE: • Install to the left side of vehicle first because the engine inclines to the left. • Temporarily tighten one bolt arrowed in the figure.

Tightening torque: 75 N·m (7.6 kgf-m, 55.3 ft-lb)

AT-05144

CVT-72

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

15) Set the ST1 to vehicle body and lift up the engine unit slightly. ST1 99099AJ000 ENGINE HANGER ST2 99099AJ010 CHAIN BALANCER CAUTION: • Set so that the chain sling does not hit the engine parts. • Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.

ST2

ST1

AT-05514

16) Remove the bolts from ST (FRONT MOUNTING H4).

AT-05630

CVT-73

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

17) Remove the bolt and nut to remove ST (FRONT MOUNTING H4).

AT-05633

18) Temporarily attach the front engine mounting with bolts.

AT-05634

CVT-74

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

19) Install the bolt and nut to the front engine mounting.

AT-05635

20) Tighten the bolt and nut of the front engine mounting. NOTE: Start tightening from the engine side bolt.

Tightening torque: T1: 25 N·m (2.5 kgf-m, 18.4 ft-lb) T2: 45 N·m (4.6 kgf-m, 33.2 ft-lb)

T1

T1

T2

CS-01169

21) Remove the ST (ENGINE HANGER and CHAIN SLING).

CVT-75

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

22) Install the stopper rod.

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb)

CS-01155

23) Install the nut to the transmission mounting bracket.

Tightening torque: 45 N·m (4.6 kgf-m, 51.6 ft-lb)

AT-05622

24) Remove the ST (STOPPER SET) from converter case. 25) Match the torque converter screw hole with drive plate hole to install the bolt. CAUTION: • Do not drop the mounting bolt in the converter housing. • Do not damage the mounting bolt.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

CVT-76

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

26) Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as engine revolution.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) 27) Install the service hole.

AT-05131

28) Install the starter. 29) Lift up the vehicle. 30) Tighten the single mounting bolt of transmission mounting bracket.

Tightening torque: 75 N·m (7.6 kgf-m, 55.3 ft-lb)

AT-05144

CVT-77

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

31) Set the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR

ST

AT-05145

32) Replace the circlip of the drive shaft with a new part. 33) Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR). 34) Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle. 35) Install the CVTF inlet hose and CVTF outlet hose. NOTE: Use the new CVTF inlet hose and CVTF outlet hose.

AT-05612

36) Insert the ball joint into housing and secure with bolt.

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb) CAUTION: • Do not apply grease to the tapered portion of ball stud. • Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.

CVT-78

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

37) Install the stabilizer link.

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb) 38) Connect the tie-rod end and knuckle arm, and attach the castle nut. Tightening torque: 27 N·m (2.75 kgf-m, 19.9 ft-lb) CAUTION: When connecting, do not hit the cap at the bottom of tie-rod end with hammer. 39) After tightening the castle nut to the specified tightening torque, tighten it further within 60° until the cotter pin hole is aligned with slot in the nut. Fit the cotter pin into the nut, and then bend the pin to lock.

(A)

(B)

(C) AT-05134

(A) Cotter pin (B) Tie-rod end (C) Castle nut

40) Install the propeller shaft. 41) Install the universal joint.

CVT-79

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

42) Install the plate assembly to transmission.

Tightening torque: T: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

T

(A) (B)

CS-01132

(A) Select cable (B) Plate ASSY

43) Install the washer and snap pin to shifter arm.

(B)

(D)

(C) (A) AT-05631

(A) (B) (C) (D)

Shifter arm Snap pin Select cable Washer

CVT-80

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

44) Install the heat shield cover.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CS-01104

45) Install the center exhaust pipe. 46) Install the under cover. 47) Lower the vehicle. 48) Remove the engine hanger rear for turbo model and install the engine hanger rear for non-turbo model.

Tightening torque: T1: 16 N·m (1.6 kgf-m, 11.8 ft-lb) T2: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

T1

T2

AT-05637

CVT-81

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

49) Install the engine harness connector to the engine hanger rear, and connect the harness connector, and install the harness connector bracket.

Tightening torque: 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

CS-01220

50) Install the throttle body. 51) Install the manifold absolute pressure sensor. 52) Connect the following harness connectors. • Transmission harness • Transmission radio ground terminal

Tightening torque: 13 N·m (1.3 kgf-m, 9.6 ft-lb)

(A) (B)

AT-05128

(A) Transmission harness connectors (B) Transmission radio ground terminal

CVT-82

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

53) Install the battery cable bracket, and install the battery cable clip to the bracket.

Tightening torque: 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

AT-05611

54) Attach the grille bracket.

AT-05636

55) Install the air intake boot assembly. 56) Install the air intake duct. 57) Install the front wheels. 58) Connect the ground cable to battery. 59) Refill differential gear oil to adjust the differential gear oil amount. 60) Refill CVTF to adjust the CVTF amount. 61) Perform the variator chain break-in. CAUTION: Always execute the variator chain break-in at the replacement of the following. • Variator chain replacement • Primary pulley and secondary pulley replacement 62) Perform Clear Memories 2 operation. 63) Execute the learning control promotion.

CVT-83

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Automatic Transmission Assembly CONTINUOUSLY VARIABLE TRANSMISSION

64) Execute the rear differential inspection mode. CAUTION: Always execute the rear differential inspection mode at the replacement of the following. • Replacement of transmission assembly • Replacement of front differential hypoid gear set 65) Perform the road test to make sure there is no fault.

CVT-84

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Transmission Mounting System CONTINUOUSLY VARIABLE TRANSMISSION

12.Transmission Mounting System A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the center exhaust pipe. 4) Remove the heat shield cover.

CS-01104

5) Set the transmission jack under the transmission. Make sure that the support plate of transmission jack does not touch the oil pan. 6) Remove the transmission rear crossmember.

AT-05139

7) Remove the rear cushion rubber.

CVT-85

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Transmission Mounting System CONTINUOUSLY VARIABLE TRANSMISSION

B: INSTALLATION 1) Attach the rear cushion rubber to the transmission.

Tightening torque: 40 N·m (4.1 kgf-m, 29.5 ft-lb) 2) Install the crossmember. Tightening torque: T1: 35 N·m (3.6 kgf-m, 25.8 ft-lb) T2: 75 N·m (7.6 kgf-m, 55.3 ft-lb)

T2

T1

T2

AT-05143

3) Remove the transmission jack. 4) Install the heat shield cover.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CS-01104

5) Install the center exhaust pipe. 6) Connect the ground cable to battery.

CVT-86

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Transmission Mounting System CONTINUOUSLY VARIABLE TRANSMISSION

C: INSPECTION • Check the crossmember for bends or damage. • Check that the cushion rubber is not stiff, cracked or otherwise damaged.

CVT-87

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Extension Case Oil Seal CONTINUOUSLY VARIABLE TRANSMISSION

13.Extension Case Oil Seal A: INSPECTION Check for leakage of CVTF from the joint section of transmission and propeller shaft. If a leak is found, inspect the propeller shaft and replace the oil seal.

B: REPLACEMENT CAUTION: Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself. 1) Lift up the vehicle. 2) Clean the transmission exterior. 3) Remove the center exhaust pipe. 4) Remove the heat shield cover.

CS-01104

5) Remove the propeller shaft. 6) Using a screwdriver or ST, remove the oil seal trying not to damage the extension case. ST 398527700 PULLER ASSY 7) Using the ST, install the oil seal. NOTE: Use a new oil seal. ST 498057300 OIL SEAL DRIFT 8) Install the propeller shaft.

CVT-88

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Extension Case Oil Seal CONTINUOUSLY VARIABLE TRANSMISSION

9) Install the heat shield cover.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CS-01104

10) Install the center exhaust pipe. 11) Adjust the CVTF level and check there is no leakage.

CVT-89

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Differential Side Retainer Oil Seal CONTINUOUSLY VARIABLE TRANSMISSION

14.Differential Side Retainer Oil Seal A: INSPECTION Check for leakage of gear oil from differential side retainer oil seal part. If there is an oil leak, inspect the front drive shaft and replace the oil seal.

B: REPLACEMENT CAUTION: • Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself. • Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or fire. If differential gear oil is spilled on the exhaust pipe, wipe it off completely. 1) Lift up the vehicle, and remove the front wheels. 2) After pulling off the cotter pin and removing the castle nut, use a puller to remove the tie-rod end from the knuckle arm.

(A)

(B)

(C) AT-05134

(A) Cotter pin (B) Tie-rod end (C) Castle nut

3) Lift up the vehicle. 4) Remove the center exhaust pipe.

CVT-90

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Differential Side Retainer Oil Seal CONTINUOUSLY VARIABLE TRANSMISSION

5) Remove the differential gear oil drain plug using TORX® bit T70, and then drain differential gear oil.

(A)

AT-05127

(A) Differential gear oil drain plug

6) Tighten the differential gear oil drain plug. NOTE: Use a new gasket.

Tightening torque: 70 N·m (7.1 kgf-m, 51.6 ft-lb) 7) Remove the stabilizer link. 8) Disconnect the ball joint and housing. 9) Holding the joint of front drive shaft from transmission side, pull out the drive shaft from transmission with care not to stretch the boot. 10) Remove the differential side retainer oil seal using driver wrapped with vinyl tape etc.

CVT-91

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Differential Side Retainer Oil Seal CONTINUOUSLY VARIABLE TRANSMISSION

11) Using the ST, install the differential side retainer oil seal by lightly tapping with a hammer. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE: • Apply differential gear oil to the oil seal lips. • Oil seal has an identification mark (R, L). When installing oil seals, do not confuse the left and right.

ST

AT-05142

12) Set the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR

ST

AT-05145

13) Replace the circlip of the drive shaft with a new part. 14) Insert the front drive shaft spline section into transmission and remove the ST (DIFFERENTIAL SIDE OIL SEAL INSTALLER). 15) Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.

CVT-92

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Differential Side Retainer Oil Seal CONTINUOUSLY VARIABLE TRANSMISSION

16) Insert the ball joint into housing and secure with bolt.

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb) CAUTION: • Do not apply grease to the tapered portion of ball stud. • Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact. 17) Install the stabilizer link.

Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb) 18) Install the center exhaust pipe. 19) Lower the vehicle. 20) Connect the tie-rod end and knuckle arm, and attach the castle nut. Tightening torque: 27 N·m (2.75 kgf-m, 19.9 ft-lb) CAUTION: When connecting, do not hit the cap at the bottom of tie-rod end with hammer. 21) After tightening the castle nut to the specified tightening torque, tighten it further within 60° until the cotter pin hole is aligned with slot in the nut. Fit the cotter pin into the nut, and then bend the pin to lock.

(A)

(B)

(C) AT-05134

(A) Cotter pin (B) Tie-rod end (C) Castle nut

22) Refill differential gear oil from the charge pipe. 23) Adjust the level of differential gear oil. 24) Install the front wheels.

CVT-93

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Inhibitor Switch CONTINUOUSLY VARIABLE TRANSMISSION

15.Inhibitor Switch A: INSPECTION When the driving condition or starter motor operation is improper, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Remove the air intake boot assembly. 2) Disconnect the inhibitor harness connector.

AT-05146

3) Check for continuity in inhibitor switch circuit by shifting the select lever in “P”, “R”, “N” and “D” respectively. NOTE: • Check that there is no continuity in the ignition circuit when the select lever is in the “R” and “D” ranges. • When inhibitor switch is normal, check there is no poor contact in vehicle side connector and no open circuit in harness.

Signal sent to TCM

Starter circuit Back-up light circuit

Range P R N

Terminal No. 4—3 4—2 4—1

D P/N R

4—8 12 — 11 10 — 9

CVT-94

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Inhibitor Switch CONTINUOUSLY VARIABLE TRANSMISSION

(A)

4 3 2 1 8 7 6 5 12 11 10 9

AT-05147

(A) Inhibitor harness connector

4) Check that there is continuity at equal points when the select lever is tilted 1.5° in both directions from the “N” range. If there is continuity in only one direction or in other points, adjust the inhibitor switch.

P

R (C)

N

M

(A) (B) (A)

D AT-05604

(A) Continuity does not exist. (B) Continuity exists. (C) 1.5°

5) Repeat the above inspection in other gear ranges. If there is fault, adjust the inhibitor switch and select cable.

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Inhibitor Switch CONTINUOUSLY VARIABLE TRANSMISSION

B: ADJUSTMENT 1) Shift the select lever to “N” range. 2) Loosen the two bolts holding the inhibitor switch. 3) Insert the ST vertically into the holes of the shifter arm and switch body. ST 499267300 STOPPER PIN

ST

AT-05149

4) Tighten the two bolts holding the inhibitor switch.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb) 5) Repeat the inspection of the inhibitor switch. If the inhibitor switch is determined to be “faulty”, replace it.

CVT-96

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Inhibitor Switch CONTINUOUSLY VARIABLE TRANSMISSION

C: REMOVAL 1) Set the vehicle on a lift. 2) Shift the select lever to “N” range. 3) Disconnect the ground cable from battery. 4) Lift up the vehicle. 5) Remove the center exhaust pipe. 6) Remove the snap pin and washer from the shifter arm.

(B)

(E)

(C) (D)

(A) CS-01128

(A) (B) (C) (D) (E)

Shifter arm Snap pin Select cable Plate ASSY Washer

7) Using the ST, remove the spring pin and shifter arm. ST 398791600 REMOVER

(B) (A)

AT-05150

(A) Spring pin (B) Shifter arm

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Inhibitor Switch CONTINUOUSLY VARIABLE TRANSMISSION

8) Remove the inhibitor harness connector from inhibitor switch. 9) Remove the two inhibitor switch securing bolts.

AT-05151

10) Remove the inhibitor switch from the transmission case.

D: INSTALLATION 1) Install the inhibitor switch to the transmission case temporarily.

AT-05151

2) Connect the inhibitor harness connector to the inhibitor switch.

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Inhibitor Switch CONTINUOUSLY VARIABLE TRANSMISSION

3) Install the shifter arm and fix with the spring pin. NOTE: Use new spring pin.

(B) (A)

AT-05150

(A) Spring pin (B) Shifter arm

4) Shift the shifter arm to “N” range. 5) Install the ST vertically in the cutout of shifter arm and the hole of switch body. ST 499267300 STOPPER PIN

ST

AT-05149

6) Tighten the two bolts holding the inhibitor switch.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb) 7) Install the select cable to the shifter arm.

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Inhibitor Switch CONTINUOUSLY VARIABLE TRANSMISSION

8) Install the washer and snap pin to the shifter arm.

(B)

(E)

(C) (D)

(A) CS-01128

(A) (B) (C) (D) (E)

Shifter arm Snap pin Select cable Plate ASSY Washer

9) Install the center exhaust pipe. 10) Lower the vehicle. 11) Connect the ground cable to battery. 12) Check the inhibitor switch.

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Secondary Speed Sensor CONTINUOUSLY VARIABLE TRANSMISSION

16.Secondary Speed Sensor A: REMOVAL CAUTION: Be sure to prevent water or oil from contacting the connector terminal of secondary speed sensor. If adhesion occurs, replace with a new part. 1) Remove the transmission from the vehicle. 2) Remove the transmission cover on the transmission upper side.

AT-05183

3) Remove the harness connector from secondary speed sensor. 4) Remove the secondary speed sensor.

AT-05152

B: INSTALLATION CAUTION: Be sure to prevent water or oil from contacting the connector terminal of secondary speed sensor. If adhesion occurs, replace with a new part. Install in the reverse order of removal.

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Secondary Speed Sensor CONTINUOUSLY VARIABLE TRANSMISSION

NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

Tightening torque: Secondary speed sensor 5 N·m (0.5 kgf-m, 3.7 ft-lb) Transmission cover 8 N·m (0.8 kgf-m, 5.9 ft-lb)

C: INSPECTION 1) Remove the instrument panel lower cover. 2) Set the probe of oscilloscope to TCM harness connector.

(A) A: B54

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

(B) AT-05605

(A) + probe (B) – probe

3) Start and warm up the engine. 4) Check the waveform of secondary speed sensor with engine idling. (V)

10

5

0

5 0

10

20

30

CVT-102

40

(ms)

AT-05485

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Primary Speed Sensor CONTINUOUSLY VARIABLE TRANSMISSION

17.Primary Speed Sensor A: REMOVAL CAUTION: Be sure to prevent water or oil from contacting the connector terminal of primary speed sensor. If adhesion occurs, replace with a new part. 1) Remove the air intake boot assembly. 2) Remove the harness connector from primary speed sensor. 3) Remove the primary speed sensor.

AT-05155

B: INSTALLATION CAUTION: Be sure to prevent water or oil from contacting the connector terminal of primary speed sensor. If adhesion occurs, replace with a new part. Install in the reverse order of removal. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

CVT-103

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Primary Speed Sensor CONTINUOUSLY VARIABLE TRANSMISSION

C: INSPECTION 1) Remove the instrument panel lower cover. 2) Set the probe of oscilloscope to TCM harness connector.

(A)

(B)

A: B54

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

AT-05606

(A) + probe (B) – probe

3) Start and warm up the engine. 4) Check the waveform of primary speed sensor with engine idling. (V)

10

5

0

5 0

5

10

15

CVT-104

20

(ms)

AT-05483

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Front Wheel Speed Sensor CONTINUOUSLY VARIABLE TRANSMISSION

18.Front Wheel Speed Sensor A: REMOVAL CAUTION: • Be sure to prevent water or oil from contacting the connector terminal of front wheel speed sensor. If adhesion occurs, replace with a new part. • When removing front wheel speed sensor, CVTF may let out. If CVTF has leaked, adjust the CVTF level after installing the front wheel speed sensor. 1) Lift up the vehicle. 2) Clean the transmission exterior. 3) Remove the harness connector from front wheel speed sensor. 4) Remove the front wheel speed sensor.

AT-05160

B: INSTALLATION CAUTION: • Be sure to prevent water or oil from contacting the connector terminal of front wheel speed sensor. If adhesion occurs, replace with a new part. • After installing the front wheel speed sensor, adjust the CVTF level. Install in the reverse order of removal. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

Tightening torque: 5 N·m (0.5 kgf-m, 5.2 ft-lb)

CVT-105

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Front Wheel Speed Sensor CONTINUOUSLY VARIABLE TRANSMISSION

C: INSPECTION 1) Remove the instrument panel lower cover. 2) Set the probe of oscilloscope to TCM harness connector.

(B) A: B54

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

(A) AT-05608

(A) + probe (B) – probe

3) Lift up the vehicle and raise the vehicle speed up to 20 km/h (12 MPH). 4) Check the waveform of front wheel speed sensor when vehicle speed is at 20 km/h (12 MPH). (V)

10

5

0

5 0

10

20

30

CVT-106

40

(ms)

AT-05484

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Secondary Pressure Sensor CONTINUOUSLY VARIABLE TRANSMISSION

19.Secondary Pressure Sensor A: REMOVAL CAUTION: • Be sure to prevent water or oil from contacting the connector terminal of secondary pressure sensor. If adhesion occurs, replace with a new part. • When removing secondary pressure sensor, CVTF may let out. If CVTF has leaked, adjust the CVTF level after installing the secondary pressure sensor. 1) Remove the air intake boot assembly. 2) Remove the secondary pressure sensor connector. 3) Remove the secondary pressure sensor. NOTE: Use Ko-ken 3/8 12-point 27 mm (manufacturer product No. 3305M-27) deep socket.

AT-05158

B: INSTALLATION CAUTION: • Be sure to prevent water or oil from contacting the connector terminal of secondary pressure sensor. If adhesion occurs, replace with a new part. • After installing the secondary pressure sensor, adjust the CVTF level. Install in the reverse order of removal. NOTE: Use new O-rings.

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb)

CVT-107

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Secondary Pressure Sensor CONTINUOUSLY VARIABLE TRANSMISSION

C: INSPECTION NOTE: Leave it for 10 minutes or more after the engine stops, and then perform the inspection. 1) Remove the instrument panel lower cover. 2) Check that the CVTF temperature is 10 — 80°C (50 — 176°F) using the Subaru Select Monitor. 3) Check the power supply voltage of the secondary pressure sensor.

Connector & terminal (B54) No. 2 (+) — No. 15 (–): Specification 4.8 — 5.2 V

A: B54

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

AT-08176

4) Check the voltage of the secondary pressure sensor.

Connector & terminal (B54) No. 17 (+) — No. 15 (–): Specification 0.45 — 0.55 V

A: B54

13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14

AT-05607

CVT-108

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Control Valve Body CONTINUOUSLY VARIABLE TRANSMISSION

20.Control Valve Body A: REMOVAL CAUTION: • Directly after the vehicle has been running or the engine has been long idle running, the CVTF is hot. Be careful not to burn yourself. • Be careful not to spill differential gear oil on the exhaust pipe to prevent it from emitting smoke or causing a fire. If gear oil adheres, wipe it off completely. NOTE: The control valve body is replaced as an assembly only, because it is a non-disassembly part. 1) Lift up the vehicle. 2) Clean the transmission exterior. 3) Remove the CVTF drain plug to drain CVTF.

(A)

AT-05121

(A) CVTF drain plug

4) Install the CVTF drain plug. NOTE: Use a new gasket.

Tightening torque: 20 N·m (2.1 kgf-m, 14.8 ft-lb)

CVT-109

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Control Valve Body CONTINUOUSLY VARIABLE TRANSMISSION

5) Remove the oil pan. CAUTION: Be careful not to allow foreign matter such as dust or dirt to enter the oil pan.

AT-05163

6) Remove the magnet. 7) Completely remove the remaining liquid gasket on the transmission case and oil pan. 8) Disconnect the control valve harness connector.

AT-05164

CVT-110

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Control Valve Body CONTINUOUSLY VARIABLE TRANSMISSION

9) Remove the oil strainer.

AT-05165

10) Remove the control valve body. CAUTION: Do not let the manual valve drop off.

AT-05166

CVT-111

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Control Valve Body CONTINUOUSLY VARIABLE TRANSMISSION

11) Remove the pressure pipe. NOTE: It may be located in transmission case side.

AT-05168

12) Remove the O-ring from oil strainer.

AT-05167

CVT-112

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Control Valve Body CONTINUOUSLY VARIABLE TRANSMISSION

13) Remove the O-ring from pressure pipe.

AT-05190

B: INSTALLATION 1) Clean the mating surface of oil pan and transmission case. 2) Check the control valve body for dust and other foreign matter. 3) Install the O-ring to the pressure pipe. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

AT-05190

CVT-113

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Control Valve Body CONTINUOUSLY VARIABLE TRANSMISSION

4) Install the pressure pipe.

AT-05168

5) Install the control valve body to the transmission. CAUTION: • Beware of the transmission harness getting caught in between. • Do not impact or bend the transmission harness because it has the oil temperature sensor inside. NOTE: • Engage the manual valve to the manual plate. • Lead the transmission harness through from the point indicated by dashed line in the figure.

Tightening torque: 9 N·m (0.9 kgf-m, 6.6 ft-lb)

(B)

(A) (A)

(A) (A)

(A) (A) (A)

(A) (A)

(A)

(A)

AT-05478

(A) Short bolt (11 pcs) (B) Long bolt (1 pcs)

CVT-114

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Control Valve Body CONTINUOUSLY VARIABLE TRANSMISSION

6) Install the O-ring to oil strainer and install the oil strainer. NOTE: • Use new O-rings. • Apply CVTF to the O-ring. • Let the transmission harness run between control valve body and oil strainer.

Tightening torque: 9 N·m (0.9 kgf-m, 6.6 ft-lb)

AT-05165

7) Connect the control valve harness connector.

AT-05164

8) Clean the magnet.

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Control Valve Body CONTINUOUSLY VARIABLE TRANSMISSION

9) Attach the magnet at the specified position of the oil pan.

AT-05169

10) Apply liquid gasket all around the oil pan mating surface seamlessly.

Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent

AT-05170

CVT-116

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Control Valve Body CONTINUOUSLY VARIABLE TRANSMISSION

11) Install the oil pan by equally tightening the bolts. CAUTION: Beware of the transmission harness getting caught in between.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

AT-05163

12) Fill with CVTF. 13) Adjust the CVTF level.

CVT-117

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Control Valve Body CONTINUOUSLY VARIABLE TRANSMISSION

C: INSPECTION • Check each part for damage or dust. • Check oil strainer for clogging. • Measure the resistance of each solenoid. NOTE: Measurement should be performed at a temperature of 20°C (68°F).

4 3 2 1 8 7 6 5

AT-05172

Solenoid Secondary solenoid Lock-up duty solenoid F&R solenoid Lock-up ON/OFF solenoid Primary DOWN solenoid Primary UP solenoid AWD solenoid

Specification (Ω)

Terminal No. No. 1 - control valve body No. 2 - control valve body No. 3 - control valve body No. 5 - control valve body No. 6 - control valve body No. 7 - control valve body No. 8 - control valve body

CVT-118

Approx. 6.6 Ω Approx. 12 Ω Approx. 5.3 Ω Approx. 16 Ω Approx. 12 Ω Approx. 12 Ω Approx. 3.2 Ω

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Transmission Harness CONTINUOUSLY VARIABLE TRANSMISSION

21.Transmission Harness A: REMOVAL 1) Remove the transmission from the vehicle. 2) Remove the transmission harness ground terminal and remove the harness connectors from front wheel speed sensor and secondary speed sensor.

AT-05455

3) Remove the harness connectors from inhibitor switch, primary speed sensor and secondary pressure sensor.

AT-05452

CVT-119

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Transmission Harness CONTINUOUSLY VARIABLE TRANSMISSION

4) Remove the transmission harness stay.

AT-05453

5) Remove transmission harness connector and inhibitor harness connector from harness stay. 6) Remove the control valve body. 7) Remove the mounting bolt to pull out the bushing of transmission harness from transmission case round hole.

AT-05454

8) Remove the harness clip from transmission assembly.

CVT-120

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Transmission Harness CONTINUOUSLY VARIABLE TRANSMISSION

B: INSTALLATION Install in the reverse order of removal. NOTE: • Use new O-rings. • Do not impact or bend the transmission harness because it has the oil temperature sensor inside. • Install the transmission ground terminal at an angle of 45° approximately.

Tightening torque: T1: 5 N·m (0.5 kgf-m, 3.7 ft-lb) T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

T2

T2

(A)

T1 AT-05646

(A) Install at an angle of 45° approximately.

C: INSPECTION 1) Visually check the harness and connector for damage or crack. 2) Check the harness terminal for rust, disconnection or poor contact. 3) Check the continuity between harness terminals and oil temperature sensor. NOTE: Refer to WIRING SECTION for transmission harness terminal and oil temperature sensor terminal.

Harness continuity standard Less than 1 Ω Oil temperature sensor standard Approx. 2.6 kΩ (at 20°C)

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Transmission Control Module (TCM) CONTINUOUSLY VARIABLE TRANSMISSION

22.Transmission Control Module (TCM) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. 3) Remove the bulkhead harness connector from TCM. 4) Remove the TCM. NOTE: Replace TCM and bracket as a set.

AT-05610

CVT-122

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Transmission Control Module (TCM) CONTINUOUSLY VARIABLE TRANSMISSION

B: INSTALLATION 1) Install the TCM to the bracket. CAUTION: To avoid the damage to bracket and TCM, do not remove after installing TCM to bracket. If installed by mistake, the part must be replaced with a new part. 2) Install the TCM.

Tightening torque: 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

AT-05610

3) Install the harness connector to TCM. 4) Install the instrument panel lower cover. 5) Execute the learning control promotion.

CVT-123

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CVTF Cooler Pipe and Hose CONTINUOUSLY VARIABLE TRANSMISSION

23.CVTF Cooler Pipe and Hose A: REMOVAL CAUTION: • Immediately after the vehicle has been running or after idling for a long time, the CVTF will be hot. Be careful not to burn yourself. • If the CVTF is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. • When removing the CVTF cooler pipe assembly on vehicle side, be careful not to bend the A/C pipe. 1) Lift up the vehicle. 2) Remove the under cover. 3) Remove the CVTF inlet hose and CVTF outlet hose.

AT-05612

4) Lift up the vehicle. 5) Remove the inlet hose and outlet hose on radiator side. CAUTION: Do not use a screwdriver or other pointed tools.

AT-05177

CVT-124

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CVTF Cooler Pipe and Hose CONTINUOUSLY VARIABLE TRANSMISSION

6) Remove the CVTF inlet pipe and CVTF outlet pipe.

(A)

(B)

AT-05178

(A) CVTF outlet pipe (B) CVTF inlet pipe

7) Lower the vehicle. 8) Remove the battery. 9) Remove the battery cable clip from the bracket, and remove the battery cable bracket.

AT-05611

10) Remove the front bumper. (OUTBACK model) 11) Remove the headlight assembly (LH). (OUTBACK model)

CVT-125

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CVTF Cooler Pipe and Hose CONTINUOUSLY VARIABLE TRANSMISSION

12) Remove the inlet hose and outlet hose. (OUTBACK model)

AT-05615

13) Remove the CVTF cooler pipe assembly mounting bolt.

AT-05507

CVT-126

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CVTF Cooler Pipe and Hose CONTINUOUSLY VARIABLE TRANSMISSION

14) Remove the sensor cover plate. (OUTBACK model)

AB-02341

15) Remove the front sub sensor harness connector and front harness clip from the vehicle, and route them under the CVTF cooler pipe assembly. (OUTBACK model) CAUTION: Refer to “CAUTION” of “General Description” before replacing the front sub sensor harness connector.

AT-05625

CVT-127

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CVTF Cooler Pipe and Hose CONTINUOUSLY VARIABLE TRANSMISSION

16) Detach the A/C pipe from clip.

AT-05506

17) Remove the CVTF cooler pipe assembly from the vehicle.

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CVTF Cooler Pipe and Hose CONTINUOUSLY VARIABLE TRANSMISSION

B: INSTALLATION CAUTION: When installing the CVTF cooler pipe assembly on vehicle side, be careful not to bend the A/C pipe. 1) Temporarily attach the CVTF cooler pipe assembly to vehicle. 2) Route the front harness above the CVTF cooler pipe assembly, and install the harness clip to the vehicle, and connect the front sub sensor harness connector. (OUTBACK model)

AT-05625

3) Attach the sensor cover plate. (OUTBACK model) 4) Fix the CVTF cooler pipe assembly to vehicle.

Tightening torque: 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

AT-05507

5) Install the A/C pipe to clip.

CVT-129

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CVTF Cooler Pipe and Hose CONTINUOUSLY VARIABLE TRANSMISSION

6) Install the inlet hose and outlet hose. (OUTBACK model) NOTE: Use the new inlet hose and outlet hose.

AT-05615

7) Install the headlight assembly (LH). (OUTBACK model) 8) Install the front bumper. (OUTBACK model) 9) Install the battery cable bracket, and install the battery cable clip to the bracket.

Tightening torque: 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

AT-05611

10) Lift up the vehicle.

CVT-130

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CVTF Cooler Pipe and Hose CONTINUOUSLY VARIABLE TRANSMISSION

11) Install the CVTF inlet pipe and CVTF outlet pipe. NOTE: Use a new gasket.

Tightening torque: T1: 16 N·m (1.6 kgf-m, 11.8 ft-lb) T2: 40 N·m (4.1 kgf-m, 29.5 ft-lb)

(A) T1

T2

(B) T2

AT-05662

(A) CVTF outlet pipe (B) CVTF inlet pipe

12) Install the CVTF inlet hose and CVTF outlet hose. NOTE: Use the new CVTF inlet hose and CVTF outlet hose.

AT-05612

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CVTF Cooler Pipe and Hose CONTINUOUSLY VARIABLE TRANSMISSION

13) Install the inlet hose and outlet hose on radiator side. NOTE: Use the new inlet hose and outlet hose.

AT-05177

14) Install the under cover. 15) Lower the vehicle. 16) Install the battery. 17) Adjust the CVTF level and check there is no leakage.

C: INSPECTION Repair or replace any faulty hoses, pipes, clamps, and washers found in the inspection below. • Check for CVTF leaks in joints between the transmission, radiator, CVTF oil cooler (OUTBACK model), pipes, and hoses. • Check the clamp for deformation. • Lightly bend the hose and check for cracks in the surface or other damages. • Pinch the hose with your fingers and check for poor elasticity. Also check for poor elasticity in the parts where the clamp was installed by pressing with your fingernail. • Check for peeling, cracks, and deformation at the tip of the hose.

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CVT Oil Cooler CONTINUOUSLY VARIABLE TRANSMISSION

24.CVT Oil Cooler A: REMOVAL 1) Remove the front bumper. 2) Remove the headlight assembly (LH). 3) Remove the inlet hose and outlet hose.

AT-05615

4) Remove the CVTF oil cooler.

AT-05614

B: INSTALLATION Install in the reverse order of removal.

Tightening torque: 7.5 N·m (0.76 kgf-m, 5.5 ft-lb) NOTE: Use the new inlet hose and outlet hose.

C: INSPECTION Check that the CVTF oil cooler has no deformation, cracks or other damages.

CVT-133

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Air Breather Hose CONTINUOUSLY VARIABLE TRANSMISSION

25.Air Breather Hose A: REMOVAL 1) Remove the air intake boot assembly. 2) Remove the two air breather hoses.

AT-05180

3) Remove the oil cap.

AT-05181

B: INSTALLATION Install in the reverse order of removal. NOTE: Use new O-rings.

C: INSPECTION • Check the hose for peeling, crack or clogging. • Check the oil cap is not cracked or clogged. • Check O-ring of oil cap is not damaged.

CVT-134

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Drive Plate CONTINUOUSLY VARIABLE TRANSMISSION

26.Drive Plate A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Set the ST. ST 498497100 CRANKSHAFT STOPPER

AT-05184

3) Remove the drive plate.

B: INSTALLATION 1) Temporarily tighten the drive plate. 2) Set the ST. ST 498497100 CRANKSHAFT STOPPER

AT-05184

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Drive Plate CONTINUOUSLY VARIABLE TRANSMISSION

3) Tighten the drive plate mounting bolt in three stages. NOTE: Fix the engine unit. (1) Tighten the drive plate mounting bolt.

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb) (2) Additionally tighten the drive plate mounting bolts. Tightening torque: 40 N·m (4.1 kgf-m, 29.5 ft-lb) (3) While checking the tightening angle with the ST, tighten the drive plate mounting bolts to the specified angle. Tightening angle: 30°±5° ST 18854AA000 ANGLE GAUGE 4) Install the transmission assembly to the vehicle.

C: INSPECTION Check the drive cable for damage.

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Preparation for Overhaul CONTINUOUSLY VARIABLE TRANSMISSION

27.Preparation for Overhaul A: GENERAL DESCRIPTION Before disassembling and assembling the transmission, follow the following procedures to prepare.

B: PROCEDURE 1) Clean the transmission exterior. 2) Remove the torque converter assembly. 3) Attach the ST on the transmission. ST 18632AA000 STAND ASSY ST

ST

ST

ST

AT-05182

4) Remove the transmission cover on the transmission upper side. NOTE: Install using the following tightening torque.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

AT-05183

5) Place the transmission assembly on end.

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Torque Converter Assembly CONTINUOUSLY VARIABLE TRANSMISSION

28.Torque Converter Assembly A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Pull out the torque converter assembly horizontally. CAUTION: Do not scratch the inside of engaging parts.

AT-05186

3) Remove the O-ring from the front reduction drive gear.

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Torque Converter Assembly CONTINUOUSLY VARIABLE TRANSMISSION

B: INSTALLATION 1) Install the O-ring to front reduction drive gear. NOTE: • Use new O-rings. • Apply CVTF to the O-ring. 2) While holding the torque converter assembly by hand, carefully install it into the torque converter case. NOTE: • Apply CVTF to the oil seal lip. • Do not damage the oil seal and O-ring. 3) Insert the torque converter assembly along the splines completely by gently rotating it manually. 4) Measure depth “A”, from converter case end surface to drive plate contacting surface.

Standard (A) (reference): 6.8 mm (0.268 in)

(A)

AT-05187

5) Install the transmission assembly to the vehicle.

C: INSPECTION • Check the protrusion of torque converter center (front boss) is not deformed or damaged. • Check the ring gear and exterior for break or damage.

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Extension Case CONTINUOUSLY VARIABLE TRANSMISSION

29.Extension Case A: REMOVAL 1) Remove the transmission assembly from vehicle body. 2) Remove the front wheel speed sensor. 3) Remove the harness clip, and remove the extension case. NOTE: The total number of extension case mounting bolts is ten.

AT-05191

B: INSTALLATION 1) Clean the mating surface of the extension case and intermediate case. 2) Select the thrust needle bearing. 3) Select the shim for transfer reduction driven gear. 4) Install the selected thrust needle bearing to transfer clutch assembly. NOTE: Install the thrust needle bearing in the correct direction.

AT-05192

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Extension Case CONTINUOUSLY VARIABLE TRANSMISSION

5) Attach the selected shim to transfer reduction driven gear assembly. 6) Apply liquid gasket to extension case seamlessly.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

AT-05193

7) Install the extension case.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-05191

8) Install the front wheel speed sensor. 9) Install the transmission assembly.

C: DISASSEMBLY 1) Remove the dust cover from extension case. 2) Remove the extension case oil seal from the extension case.

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Extension Case CONTINUOUSLY VARIABLE TRANSMISSION

D: ASSEMBLY 1) Press-fit the dust cover into extension case. 2) Install the extension case oil seal to extension case. ST 498057300 INSTALLER

E: INSPECTION • Check there is no leak of CVTF from the joint between extension case and intermediate case. • Check there is no damage or cracks on the extension case.

F: ADJUSTMENT NOTE: When replacing the extension case, select the shims for rear drive shaft thrust needle bearing and transfer reduction driven gear.

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Rear Drive Shaft CONTINUOUSLY VARIABLE TRANSMISSION

30.Rear Drive Shaft A: REMOVAL 1) Remove the transmission assembly from vehicle body. 2) Remove the extension case. 3) Remove the rear drive shaft.

AT-05194

B: INSTALLATION 1) Select the thrust needle bearing. 2) Install the selected thrust needle bearing to transfer clutch assembly. NOTE: Install the thrust needle bearing in the correct direction.

AT-05192

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Rear Drive Shaft CONTINUOUSLY VARIABLE TRANSMISSION

3) Install the rear drive shaft.

AT-05194

4) Install the extension case. 5) Install the transmission assembly to the vehicle.

C: DISASSEMBLY 1) Remove the ball bearing using ST. ST 498077600 REMOVER

ST

AT-05196

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Rear Drive Shaft CONTINUOUSLY VARIABLE TRANSMISSION

D: ASSEMBLY 1) Using the ST, install the ball bearing. NOTE: • Use a new ball bearing. • Apply CVTF to press-fitting surface of ball bearing. ST 399513600 INSTALLER

ST

AT-05197

E: INSPECTION • Check each part for crack, damage or dust. • Check the ball bearing for smooth rotation. • Check the ball bearing for excessive looseness.

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Rear Drive Shaft CONTINUOUSLY VARIABLE TRANSMISSION

F: ADJUSTMENT NOTE: When replacing the rear drive shaft or bearing, select the thrust needle bearing. 1) Using the ST, measure the distance “A” from ST end face to rear drive shaft thrust needle bearing catch surface. ST 398643600 GAUGE ST

A

AT-05198

2) Using the ST, measure the height “B” from the intermediate case mating surface to the ST end face. NOTE: Place the measurement tool at the dent on ST upper side to measure. ST 499737100 GAUGE ST

B

AT-05199

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Rear Drive Shaft CONTINUOUSLY VARIABLE TRANSMISSION

3) Using the ST, measure the height “C” from ST end face to transfer clutch assembly thrust needle bearing catch surface. NOTE: Place the measurement tool at the dent on ST upper side to measure. ST 499737100 GAUGE ST

C

AT-05200

4) Obtain the thickness of shim using the following formula to select the thrust bearing. T mm = (A – 15) – (B – C) – (0.05 — 0.25) [T in = (A – 0.59) – (B – C) – (0.002 — 0.01)] T: Thrust bearing thickness A: Height from the ST end face to the rear drive shaft thrust needle bearing catch surface B: Height from the mating surface of the intermediate case to the ST end face C: Height from the ST end face to the transfer clutch assembly thrust needle bearing catch surface 0.05 — 0.25 mm (0.002 — 0.01 in): Clearance Part number 806536020 806535030 806535040 806535050 806535060 806535070 806535090

Thrust bearing Thickness mm (in) 3.8 (0.15) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.8 (0.189) 5.0 (0.197)

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

31.Transfer Clutch A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the extension case. 3) Remove the rear drive shaft. 4) Remove the thrust needle bearing and needle bearing.

AT-05201

5) Remove the transfer clutch assembly.

AT-05202

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

6) Remove the seal ring from transfer clutch assembly.

AT-05203

B: INSTALLATION 1) Apply vaseline to the seal ring and attach it to the seal ring groove of transfer clutch assembly. NOTE: • Use a new seal ring. • When installing the seal ring, do not expand the seal ring too much.

AT-05203

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

2) Install the transfer clutch assembly.

AT-05202

3) Select the thrust needle bearing. 4) Install the selected thrust needle bearing and needle bearing to transfer clutch assembly. NOTE: Install the thrust needle bearing in the correct direction.

AT-05192

5) Install the rear drive shaft. 6) Install the extension case. 7) Install the transmission assembly to the vehicle.

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

C: DISASSEMBLY 1) Remove the snap ring, and then remove the retaining plate, drive plate and driven plate.

(A) AT-05205

(A) Snap ring

2) Using the ST, remove the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL

ST

(A)

(B) AT-05206

(A) Snap ring (B) Transfer clutch piston seal

3) Remove the transfer clutch piston seal.

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

4) Remove the return spring.

AT-05207

5) Remove the transfer clutch piston by blowing compressed air through transfer clutch assembly hole. NOTE: Block the hole opposite to the one to be blown with compressed air by your finger.

AT-05208

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

6) Using ST, remove transfer drive gear, parking gear and ball bearing. ST 18767AA000 BEARING REMOVER NOTE: Let the ST sit on the parking gear.

ST

AT-05204

7) Remove the snap ring from transfer reduction drive gear.

AT-05209

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

8) Using the ST, remove the parking gear from transfer reduction drive gear. ST1 499277100 BUSHING 1-2 INSTALLER ST2 18767AA000 BEARING REMOVER ST1

ST2

AT-05210

D: ASSEMBLY 1) Using the ST, install the parking gear to transfer reduction drive gear. ST 398177700 INSTALLER

ST

AT-05211

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

2) Install the snap ring to transfer reduction drive gear.

AT-05209

3) Using the ST, install the transfer reduction drive gear to transfer reduction drive gear shaft. ST 499277100 BUSHING 1-2 INSTALLER

ST

AT-05212

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

4) Using the ST, install the ball bearing. NOTE: Use a new ball bearing. ST 499277100 BUSHING 1-2 INSTALLER

ST

AT-05213

5) Attach the transfer clutch piston to the reduction drive gear shaft. NOTE: Apply CVTF to the transfer clutch piston lip. 6) Install the return spring.

AT-05207

7) Install the transfer clutch piston seal.

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

8) Using the ST, install the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL

ST

(A)

(B) AT-05206

(A) Snap ring (B) Transfer clutch piston seal

9) Install the pressure plate, driven plate, drive plate and snap ring.

(A) AT-05205

(A) Snap ring

10) Before measuring clearance “A”, place same thickness shims on both sides to prevent the retaining plate from tilting.

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

11) When clearance “A” exceeds the limit for use, replace the drive plate and driven plate as a set, and select and adjust the pressure plate within the initial specified value.

Initial standard: 0.7 — 1.1 mm (0.028 — 0.043 in) Limit thickness: 1.6 mm (0.063 in)

A

AT-05214

Part number 31593AA151 31593AA161

Pressure plate Thickness mm (in) 3.3 (0.130) 3.7 (0.146)

12) Check the clearance between the snap ring and retaining plate.

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Transfer Clutch CONTINUOUSLY VARIABLE TRANSMISSION

E: INSPECTION • Inspect the drive plate facing for wear and damage. • Driven plate for discoloration (burned color) • Make sure the snap ring is not worn and the return spring has no permanent distortion, damage, or deformation. • Check the lip seal for damage. • Inspect the extension end play, and adjust it to within the standard value. 1) Before measuring clearance “A” between snap ring and retaining plate, place same thickness shims on both sides to prevent the retaining plate from tilting. 2) When clearance “A” exceeds the limit for use, replace the drive plate and driven plate as a set, and select the pressure plate within the initial specified value.

Initial standard: 0.7 — 1.1 mm (0.028 — 0.043 in) Limit thickness: 1.6 mm (0.063 in)

A

AT-05214

3) Check for tight corner braking phenomenon when the vehicle is moved forward with the steering fully turned. If tight corner braking occurs, perform the following procedures. (1) With the steering wheel held at fully turned position, drive the vehicle in “D” range and with vehicle speed at approx. 5 km/h (3 MPH) in both clockwise and counterclockwise directions for approx. ten times each, while repeating acceleration and braking intermittently. (2) If the tight corner braking phenomenon still persists, drive the vehicle again in a circle for several laps.

F: ADJUSTMENT NOTE: Refer to the Rear Drive Shaft.

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Transfer Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

32.Transfer Reduction Driven Gear A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the front wheel speed sensor, and remove the extension case. 3) Remove the transfer clutch assembly. 4) Remove the transfer reduction driven gear assembly.

AT-05215

B: INSTALLATION 1) Install the reduction driven gear assembly.

AT-05215

2) Select shims. 3) Mount the selected shim onto ball bearing. 4) Install the transfer clutch assembly. 5) Install the extension case. 6) Install the transmission assembly to the vehicle.

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Transfer Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

C: DISASSEMBLY 1) Using the ST, remove the ball bearing (large) from transfer reduction driven gear. ST1 899864100 REMOVER ST2 398497701 SEAT ST3 498077600 REMOVER

ST1

ST2

ST3

AT-05216

2) Using the ST, remove the ball bearing (small) from transfer reduction driven gear. ST1 899864100 REMOVER ST2 398497701 SEAT ST3 18720AA000 REMOVER

ST1

ST2

ST3

AT-05216

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Transfer Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

D: ASSEMBLY 1) Install the new ball bearing (large) to reduction driven gear using the ST. ST 499277100 REMOVER NOTE: • Use a new ball bearing. • Install to the splines inside transfer reduction driven gear shaft.

ST

AT-05217

2) Install the new ball bearing (small) to reduction driven gear. NOTE: Use a new ball bearing. ST 499277100 REMOVER

ST

AT-05217

E: INSPECTION • Check the ball bearing for smooth rotation. • Check the ball bearing for excessive looseness. • Make sure the gear is not broken or damaged.

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Transfer Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

F: ADJUSTMENT 1) Measure depth “A” from the ST upper face to the ball bearing catch surface. ST 398643600 GAUGE ST

ST

A

AT-05218

2) Measure height “B” from the ST to the end of the ball bearing outer ring. ST 398643600 GAUGE

ST

B

ST

AT-05219

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Transfer Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

3) Obtain the thickness of shim using the following formula to select none to two shims. T mm = (A – 15) – (B + 15) – (0.05 — 0.25) [T in = (A – 0.591) – (B + 0.591) – (0.002 — 0.01)] T: Shim thickness A: Depth from the ST upper face to the ball bearing catch surface B: Height from the ST to the end of the ball bearing outer ring 15 mm (0.591 in): Thickness of ST 0.05 — 0.25 mm (0.002 — 0.01 in): Clearance Shim Part number 31288AA190 31288AA200 31288AA210

Thickness mm (in) 0.2 (0.008) 0.3 (0.012) 0.5 (0.02)

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Parking Pawl CONTINUOUSLY VARIABLE TRANSMISSION

33.Parking Pawl A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Shift the range select lever to “N” range. 3) Remove the extension case. 4) Remove the parking pawl shaft, return spring and parking pawl.

(B)

(A)

(C) AT-05220

(A) Parking pawl shaft (B) Return spring (C) Parking pawl

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Parking Pawl CONTINUOUSLY VARIABLE TRANSMISSION

B: INSTALLATION 1) Set the range select lever to the “N” range. 2) Install the parking pawl shaft, return spring and parking pawl. NOTE: Make sure that the return spring end sticks out of parking pawl as shown in the figure (a). Make sure that the other end of return spring is in contact with the rib of intermediate case as shown in the figure (b).

(B) (b)

(a)

(A)

(C)

(b)

AT-06364

(A) Parking pawl shaft (B) Return spring (C) Parking pawl

3) Install the extension case. 4) Install the transmission assembly to the vehicle.

C: INSPECTION • Check the parking pawl for breakage or damage. • Check the return spring for fatigue.

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Intermediate Case CONTINUOUSLY VARIABLE TRANSMISSION

34.Intermediate Case A: REMOVAL 1) Remove the transmission assembly from vehicle body. 2) Remove the extension case. 3) Remove the rear drive shaft. 4) Remove the transfer clutch assembly. 5) Remove the transfer reduction driven gear assembly. 6) Remove the intermediate case. NOTE: • The total number of intermediate case mounting bolts is 14. • Inside the transmission is a single bolt (arrowed).

AT-05221

7) Remove the CVTF filter.

AT-05222

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Intermediate Case CONTINUOUSLY VARIABLE TRANSMISSION

8) Remove the O-ring from the transmission case.

AT-05295

B: INSTALLATION 1) Clean the mating surface of oil pan and transmission case. 2) Install the CVTF filter. NOTE: Apply CVTF to the O-ring.

AT-05222

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Intermediate Case CONTINUOUSLY VARIABLE TRANSMISSION

3) Install the O-ring to the transmission case. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

AT-05295

4) Apply liquid gasket to intermediate case seamlessly.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

AT-05223

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Intermediate Case CONTINUOUSLY VARIABLE TRANSMISSION

5) Install the intermediate case to the transmission case. NOTE: Make sure to install the arrowed bolt.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-05221

6) Install the transfer reduction driven gear assembly. 7) Install the transfer clutch assembly. 8) Install the rear drive shaft. 9) Install the extension case. 10) Install the transmission to vehicle.

C: DISASSEMBLY 1) Remove the CVTF filler plug. 2) Remove all plugs from intermediate case.

AT-05224

3) Remove the reverse brake assembly.

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Intermediate Case CONTINUOUSLY VARIABLE TRANSMISSION

D: ASSEMBLY 1) Install the reverse brake. 2) install all plugs to intermediate case.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) NOTE: Use new O-rings.

AT-05224

3) Install the CVTF filler plug. NOTE: Replace the gasket of CVTF filler plug with a new part after installing the transmission assembly to vehicle and adjusting CVTF fluid.

E: INSPECTION • Check the intermediate case for fissures, cracks or damage. • Check for leakage of CVTF from the connections between intermediate case and transmission case, and between intermediate case and extension case.

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CVTF Filter CONTINUOUSLY VARIABLE TRANSMISSION

35.CVTF Filter A: REMOVAL NOTE: • Although CVTF filter is a maintenance-free part, replace it if a large quantity of wear debris and metal particles are found in CVTF and CVTF filter. • For removal of CVTF filter, refer to “Intermediate Case”.

B: INSTALLATION NOTE: For removal of CVTF filter, refer to “Intermediate Case”.

C: INSPECTION • Check if a large quantity of wear debris or metal particles are in CVTF and CVTF filter. • Check for broken part or damaged O-ring.

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Reverse Brake Assembly CONTINUOUSLY VARIABLE TRANSMISSION

36.Reverse Brake Assembly A: REMOVAL NOTE: For removal of reverse brake assembly, refer to “Intermediate Case”.

B: INSTALLATION NOTE: For removal of reverse brake assembly, refer to “Intermediate Case”.

C: DISASSEMBLY 1) Remove the snap ring. 2) Remove the retaining plate, drive plate, driven plate and dish plate.

AT-05225

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Reverse Brake Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Set the ST1, ST2 and ST3 to intermediate case. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18763AA000 COMPRESSOR SHAFT ST3 18765AA000 COMPRESSOR SUPPORT ST1

ST2

ST3

AT-05226

4) Compress the return spring using the set ST to remove the snap ring.

AT-05227

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Reverse Brake Assembly CONTINUOUSLY VARIABLE TRANSMISSION

5) Using the ST, remove the snap ring and spring retainer.

(A)

(B)

AT-05228

(A) Snap ring (B) Spring retainer

6) Remove the return spring.

AT-05229

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Reverse Brake Assembly CONTINUOUSLY VARIABLE TRANSMISSION

7) Remove the reverse brake piston by blowing compressed air intermittently from intermediate case hole.

AT-05230

D: ASSEMBLY 1) Apply CVTF to the seal of reverse brake piston and install it to intermediate case.

AT-05231

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Reverse Brake Assembly CONTINUOUSLY VARIABLE TRANSMISSION

2) Install the return spring.

AT-05229

3) Install the spring retainer.

AT-05232

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Reverse Brake Assembly CONTINUOUSLY VARIABLE TRANSMISSION

4) Set the ST1, ST2 and ST3 to intermediate case. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18763AA000 COMPRESSOR SHAFT ST3 18765AA000 COMPRESSOR SUPPORT ST1

ST2

ST3

AT-05226

5) Compress the return spring using the set ST to install the snap ring.

AT-05227

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Reverse Brake Assembly CONTINUOUSLY VARIABLE TRANSMISSION

6) Check the operation of reverse brake piston by blowing compressed air intermittently from intermediate case hole.

AT-05230

7) Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table. 8) Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point. 9) Scale and record the weight “Z” of a flat board which will be put on retaining plate. NOTE: • Use a stiff board which does not bend against load as a flat board to be put on retaining plate. • Use a flat board weighing less than 84 N (8.6 kgf, 18.9 lb). 10) Put the flat board on retaining plate.

AT-05234

11) Using the following formula, read the push/pull gauge, and calculate “N”. N = 84 N (8.6 kgf, 18.9 lb) – Z 84 N (8.6 kgf, 18.9 lb) : Load applied to clutch plate Z: Flat board weight

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Reverse Brake Assembly CONTINUOUSLY VARIABLE TRANSMISSION

12) Press the center of retaining plate by applying a force of “N” or more using push/pull gauge, and then measure and record the compression amount “A”. NOTE: Measure at four points with a 90° interval and calculate the average.

A

(C)

(A) (B) (D)

AT-05235

(A) (B) (C) (D)

Drive plate Driven plate Retaining plate Dish plate

13) Install the dish plate, drive plate, driven plate and retaining plate to intermediate case. NOTE: Install the dish plate in the correct direction. 14) Measure and record the clearance “B” between the retaining plate and snap ring.

B

AT-05236

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Reverse Brake Assembly CONTINUOUSLY VARIABLE TRANSMISSION

15) Piston stroke calculation Calculate with A and B dimensions recorded before. If it exceeds the limit for use, replace with a new drive plate and adjust within the initial standard value. S mm (in) = A + B S: Piston stroke A: Compression amount of drive plate and dish plate B: Clearance between retaining plate and snap ring

Initial standard: 2.88 — 3.18 mm (0.113 — 0.125 in) Limit thickness: 3.38 mm (0.133 in) Part number 31567AB680 31567AB690 31567AB700 31579AB710

Retaining plate Thickness mm (in) 5.6 (0.220) 5.8 (0.228) 6.0 (0.236) 6.2 (0.244)

E: INSPECTION • Inspect the drive plate facing for wear and damage. • Check the driven plate for discoloration (burnt color). • Check for worn snap ring, fatigue or damaged return spring or deformed spring retainer. • Make sure the clearance between retaining plate and snap ring of reverse brake is within the limit. If it exceeds the limit, replace with a new drive plate and select and adjust the retaining plate within the initial standard value.

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

37.Forward Clutch Assembly A: REMOVAL 1) Remove the transmission from the vehicle. 2) Remove the extension case. 3) Remove the rear drive shaft. 4) Remove the transfer clutch assembly. 5) Remove the transfer reduction driven gear. 6) Remove the intermediate case. 7) Remove the thrust needle bearing.

AT-05237

8) Remove the forward clutch assembly.

AT-05238

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

9) Remove the washer.

AT-05239

B: INSTALLATION 1) Select a washer. 2) Install the selected washer.

AT-05239

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Install the forward clutch assembly.

AT-05238

4) Install the thrust needle bearing. NOTE: Install the thrust needle bearing in the correct direction.

AT-05240

5) Install the intermediate case. 6) Install the transfer reduction driven gear assembly. 7) Install the transfer clutch assembly. 8) Install the rear drive shaft. 9) Install the extension case. 10) Install the transmission to vehicle.

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

C: DISASSEMBLY 1) Remove the planetary carrier assembly.

AT-05242

2) Remove the thrust needle bearing.

AT-05243

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Remove the snap ring. NOTE: Two same snap rings are used in forward clutch assembly. Use marking or labeling for measurement of the snap ring thickness when selecting the retaining plate.

AT-05244

4) Remove the internal gear.

AT-05245

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

5) Remove the sun gear.

AT-05246

6) Remove the washer.

AT-05256

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

7) Remove the thrust needle bearing.

AT-05247

8) Remove the snap ring.

AT-05248

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

9) Remove the retaining plate, drive plate, driven plate and dish plate.

AT-05249

10) Using the ST, remove the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL

ST

AT-05250

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

11) Remove the forward clutch piston seal.

AT-05251

12) Remove the return spring.

AT-05252

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

13) Remove the forward clutch piston by blowing compressed air intermittently from end of forward clutch drum.

AT-05253

D: ASSEMBLY 1) Install the forward clutch piston to forward clutch drum. NOTE: • Apply CVTF to the seal of forward clutch piston. • Insert it all the way to the end.

AT-05254

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

2) Install the return spring.

AT-05252

3) Install the forward clutch piston seal. NOTE: Apply CVTF to the sealing area of forward clutch piston seal.

AT-05251

CVT-192

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

4) Compress the return spring using the ST to install the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL

ST

AT-05250

5) Measure thickness “A” of the retaining plate installed.

A

AT-05258

CVT-193

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

6) Measure thickness “B” of internal gear on the workbench.

B

B

AT-05259

7) Measure thickness “C” of labelled or marked snap ring.

C

AT-05260

8) Install the dish plate, drive plate, driven plate and retaining plate.

CVT-194

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

9) Install the snap ring at the location (upper groove) indicated in the figure.

AT-05261

10) Measure depth “D” of snap ring and retaining plate while lifting the snap ring.

D

D

AT-05262

CVT-195

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

11) Calculate clearance “T” from internal gear to retaining plate with the obtained value from step 5) through step 10). Formula: T mm (in) = D – A – B – C

C B

T

D

A

AT-05585

12) If the value “T” obtained from step 11) exceeds the limit for use, replace the drive plate and driven plate with new parts and select the retaining plate within the initial standard value.

Initial standard: 1.2 — 1.6 mm (0.047 — 0.063 in) Limit thickness: 2.4 mm (0.09 in) Item number 31567AB670 31567AB660 31567AB650 31567AB640

Retaining plate Thickness mm (in) 3.2 (0.126) 3.0 (0.118) 2.8 (0.110) 2.6 (0.102)

13) Remove the snap ring.

AT-05261

CVT-196

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

14) Replace with the selected retaining plate. 15) Install the snap ring to the lower groove.

AT-05248

16) Install the thrust needle bearing. NOTE: Install the thrust needle bearing in the correct direction.

AT-05255

CVT-197

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

17) Install the washer.

AT-05256

18) Install the sun gear.

AT-05246

CVT-198

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

19) Install the internal gear.

AT-05245

20) Install the snap ring. 21) Install the thrust needle bearing. NOTE: Make sure to install in the right direction.

AT-05243

CVT-199

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

22) Install the planetary carrier assembly.

AT-05242

E: INSPECTION • Check the forward clutch drum, internal gear, sun gear and forward clutch piston lip for wear or damage. • Inspect the drive plate facing for wear and damage. • Check the driven plate for discoloration (burnt color). • Check for worn snap ring, fatigue or damaged return spring or deformed spring retainer. • Make sure the clearance between retaining plate and internal gear of forward clutch is within the limit. If it exceeds the standard, replace the forward clutch assembly.

F: ADJUSTMENT 1) Measure depth “A” from the ST upper face to the washer catch surface. ST 398643600 GAUGE ST

A

AT-05263

2) Install the forward clutch assembly to intermediate case.

CVT-200

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Forward Clutch Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Setting the ST, measure height “B” from the ST upper side to the immediate case mating surface. ST 499575600 GAUGE

ST

B

AT-05264

4) Obtain the thickness of washer using the following formula. Calculation formula: T (mm) = (A – 15) – (B – 15) – (0.35 — 0.70) [T (in) = (A – 0.591) – (B – 0.591) – (0.014 — 0.028)] T: Washer thickness A: Depth from the ST upper face to the washer catch surface B: Height from the upper surface of the ST to the mating surface of the intermediate case 15 mm (0.591 in): Thickness of ST 0.35 — 0.70 mm (0.014 — 0.028 in): Clearance 5) Select the washer matching value “T” obtained from step 4). Part number 803034040 803034041 803034042 803034043

Washer Washer thickness mm (in) 1.0 (0.039) 1.2 (0.047) 1.4 (0.055) 1.6 (0.063)

CVT-201

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Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

38.Reduction Driven Gear A: REMOVAL 1) Remove the transmission from the vehicle. 2) Remove the extension case. 3) Remove the rear drive shaft. 4) Remove the transfer clutch assembly. 5) Remove the transfer reduction driven gear assembly. 6) Remove the intermediate case. 7) Remove the forward clutch assembly. 8) Remove the snap ring.

AT-05265

9) Remove the reduction driven gear assembly.

AT-05266

CVT-202

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Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

10) Remove the straight pin.

AT-05267

B: INSTALLATION 1) Install the straight pin to reduction driven gear assembly.

AT-05267

CVT-203

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Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

2) Fit the straight pin portion to the recess portion of transmission case and install the reduction driven gear and install the snap ring.

AT-05266

3) Select the snap ring. 4) Install the selected snap ring. 5) Install the forward clutch assembly. 6) Install the intermediate case. 7) Install the transfer reduction driven gear assembly. 8) Install the transfer clutch assembly. 9) Install the rear drive shaft. 10) Install the extension case. 11) Install the transmission to vehicle.

CVT-204

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Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

C: DISASSEMBLY 1) Remove the bearing retainer using ST1, ST2 and ST3. ST1 899864100 REMOVER ST2 398497701 SEAT ST3 18767AA000 REMOVER

ST1

ST2

ST3

AT-05268

2) Remove the snap ring.

AT-05269

CVT-205

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Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

3) Remove the ball bearing using ST1, ST2 and ST3. ST1 899864100 REMOVER ST2 398497701 Seat ST3 498077600 REMOVER

ST1

ST2

ST3

AT-05270

D: ASSEMBLY 1) Using the ST, install the ball bearing to bearing retainer. ST 398177700 INSTALLER NOTE: • Use a new ball bearing. • Make sure to install the ball bearing in the right direction. • Apply CVTF to the press-fitting area.

ST

AT-05271

CVT-206

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Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

2) Using the ST, install the reduction driven gear. ST 499277200 INSTALLER

ST

AT-05272

E: INSPECTION • • • •

Check the ball bearing for smooth rotation. Check the ball bearing for excessive looseness. Check the reduction driven gear for breakage or damage. Check the clearance between snap ring and transmission case and replace the snap ring as necessary.

CVT-207

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Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

F: ADJUSTMENT 1) Measure clearance “A” between snap ring and transmission case.

Specification: 0.05 — 0.25 mm (0.002 — 0.01 in)

A

AT-05273

2) If clearance “A” is out of standard, select the snap ring within standard. Snap ring Part number

Thickness mm (in)

805100460 805100461 805100462 805100463 805100464

2.0 (0.079) 2.1 (0.083) 2.2 (0.087) 2.3 (0.091) 2.4 (0.094)

CVT-208

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Transmission Control Device CONTINUOUSLY VARIABLE TRANSMISSION

39.Transmission Control Device A: REMOVAL 1) Remove the transmission assembly from vehicle body. 2) Remove the oil pan and control valve body. 3) Remove the inhibitor switch. 4) Remove the spring pin. NOTE: Prevent the spring pin from dropping in the transmission using paper towel etc.

AT-05274

CVT-209

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Transmission Control Device CONTINUOUSLY VARIABLE TRANSMISSION

5) Remove the bolt and remove the range select lever, manual plate and parking rod. NOTE: Do not damage the lip of oil seal press-fitted in the case.

(D) (B) (A) (C)

AT-05275

(A) (B) (C) (D)

Bolt Range select lever Manual plate Parking rod

6) Remove the detent spring.

AT-05276

CVT-210

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Transmission Control Device CONTINUOUSLY VARIABLE TRANSMISSION

B: INSTALLATION 1) Install the detent spring to the transmission case.

Tightening torque: 7 N·m (0.7 kgf-m, 5.2 ft-lb)

AT-05276

2) Install the manual plate, parking rod, range select lever and bolt.

Tightening torque: 7 N·m (0.7 kgf-m, 5.2 ft-lb)

(D) (B) (A) (C)

AT-05275

(A) (B) (C) (D)

BOLT Range select lever Manual plate Parking rod

CVT-211

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Transmission Control Device CONTINUOUSLY VARIABLE TRANSMISSION

3) Install the spring pin. NOTE: Use new spring pin.

AT-05274

4) Install the inhibitor switch. 5) Adjust the inhibitor switch. 6) Install the control valve body and oil pan. 7) Install the transmission assembly to the vehicle.

C: INSPECTION Make sure that the manual lever and detent spring are not worn or otherwise damaged.

CVT-212

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

40.Transmission Case A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the air breather hose. 3) Remove the transmission harness. 4) Remove the secondary speed sensor. 5) Remove the inhibitor switch. 6) Remove the CVTF inlet pipe and CVTF outlet pipe. 7) Remove the extension case. 8) Remove the rear drive shaft. 9) Remove the transfer clutch assembly. 10) Remove the transfer reduction driven gear assembly. 11) Remove the intermediate case. 12) Remove the forward clutch assembly. 13) Remove the reduction driven gear. 14) Remove the oil pan and control valve body. NOTE: When removing the control valve body, also remove the pressure pipe If it is attached on the case.

AT-05277

CVT-213

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

15) Remove the CVTF pipe using a tire lever etc. NOTE: Remove by hooking the stepped portion of CVTF pipe with a tire lever etc.

(B)

(B) (A)

AT-05278

(A) CVTF pipe (B) Tire lever

16) Remove the transmission case. NOTE: The total number of transmission case mounting bolts is 15. 17) Remove the O-ring of lubrication pipe.

AT-05279

18) Remove the control device system.

CVT-214

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

B: INSTALLATION 1) Clean the mating surface of transmission case and converter case. 2) Install the control device system. 3) Install the O-ring to the lubrication pipe. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

AT-05279

4) Make sure the lubrication pipe and support rod are in vertical position.

AT-05280

CVT-215

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

5) Apply liquid gasket seamlessly to the mating surface of transmission case.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

AT-05281

6) Install the transmission case. CAUTION: If the transmission case gets in contact with the lubrication pipe and support rod, do not install the transmission case forcibly. NOTE: • Install while checking the lubrication pipe and support rod is being inserted properly into transmission case. • If installing the transmission is difficult, check if the lubrication pipe and support rod are bent. • The total number of transmission case mounting bolts is 15.

Tightening torque: 41 N·m (4.2 kgf-m, 30.2 ft-lb) 7) Install the O-ring to CVTF pipe. NOTE: Use new O-rings.

CVT-216

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

8) The smaller opening of CVTF pipe should be inserted to transmission. NOTE: After installing, make sure the CVTF pipe does not stick out of transmission case.

AT-05282

AT-05588

9) Install the reduction driven gear. 10) Install the forward clutch assembly. 11) Install the intermediate case. 12) Install the transfer reduction driven gear assembly. 13) Install the transfer clutch assembly. 14) Install the rear drive shaft. 15) Install the extension case. 16) Install the CVTF inlet pipe and CVTF outlet pipe. 17) Install the inhibitor switch. 18) Install the secondary speed sensor. 19) Install the transmission harness. 20) Install the control valve body and oil pan. 21) Install the air breather hose.

CVT-217

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

22) Install the transmission assembly to the vehicle.

C: DISASSEMBLY 1) Remove all plugs from the transmission case.

AT-05283

2) Remove the lubrication pipe.

AT-05284

CVT-218

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

3) Remove the oil seal using a screwdriver wrapped with cloth etc.

AT-05285

4) Remove the ball bearing from reduction driven gear using ST. ST 398527700 PULLER ASSY

ST

AT-05286

CVT-219

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

5) Remove the snap ring on primary pulley side.

AT-05287

6) Using the ST, remove the roller bearing on primary pulley side. NOTE: Warm up the bearing area of transmission case using a drier or heat gun. ST 398527700 PULLER ASSY

ST

AT-05288

CVT-220

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

7) Remove the snap ring on secondary pulley side.

AT-05289

8) Using the ST, remove the roller bearing on secondary pulley side. NOTE: Warm up the bearing area of transmission case using a drier or heat gun. ST 398527700 PULLER ASSY

ST

AT-05290

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

D: ASSEMBLY 1) Using the ST, install the oil seal. ST 18657AA000 INSTALLER

AT-05285

2) Using ST1 and ST2, install the ball bearing on the reduction gear side. NOTE: Use a new ball bearing. ST1 398177700 INSTALLER ST2 499755602 PRESS SNAP RING

ST2

ST1

AT-05291

CVT-222

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

3) Using ST1 and ST2, install the roller bearing on primary pulley side. NOTE: • Use a new roller bearing. • Make adjustment so that PRESS gets in contact with the center of ST2. ST1 398177700 INSTALLER ST2 20299AG010 PRESS SNAP RING

ST1

ST2

AT-05292

4) Install the snap ring on primary pulley side. NOTE: Use new snap rings.

AT-05287

CVT-223

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

5) Using ST1 and ST2, install the roller bearing on secondary pulley side. NOTE: • Use a new roller bearing. • Make adjustment so that PRESS gets in contact with the center of ST2. ST1 398177700 INSTALLER ST2 499755602 PRESS SNAP RING

ST1

ST2

AT-05293

6) Install the snap ring on secondary pulley side. NOTE: Use new snap rings.

AT-05289

CVT-224

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

7) Install all plugs. NOTE: Use new gaskets and O-rings.

Tightening torque: T1: 13 N·m (1.3 kgf-m, 9.6 ft-lb) T2: 25 N·m (2.5 kgf-m, 18.4 ft-lb) T3: 35 N·m (3.5 kgf-m, 25.8 ft-lb) T2

T1 T2

T1

T3 AT-05294

8) Install the lubrication pipe and O-ring. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

AT-05284

CVT-225

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Transmission Case CONTINUOUSLY VARIABLE TRANSMISSION

E: INSPECTION • • • • • • •

Check the transmission case for damage. Check for leakage of CVTF from the connection between converter case and transmission case. Check for leakage of CVTF from the connection between intermediate case and transmission case. Check the lubrication pipe for bend or damage. Check the ball bearing for smooth rotation. Check the bearing for seizure or wear. Apply CVTF to ball bearing and rotate the ball bearing to check for noise or dragging etc.

F: ADJUSTMENT NOTE: When replacing the transmission case with a new part, perform the following check and adjustment for the selection. • Select the thrust bearing for the forward clutch assembly. • Select the snap ring for the reduction gear.

CVT-226

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

41.Primary Pulley and Secondary Pulley A: REMOVAL NOTE: Always replace primary pulley and secondary pulley as an assembly because they are non-disassembled parts. 1) Remove the transmission assembly from the vehicle. 2) Remove the air breather hose. 3) Remove the oil pan and control valve body. 4) Remove the transmission harness. 5) Remove the extension case. 6) Remove the rear drive shaft. 7) Remove the transfer clutch assembly. 8) Remove the transfer reduction driven gear assembly. 9) Remove the intermediate case. 10) Remove the forward clutch assembly. 11) Remove the transmission case. 12) Set the ST to secondary pulley and expand the V groove of pulley to an extent that variator chain gets loose. ST 18769AA000 PULLEY EXPANDER

ST

AT-05296

13) Remove the chain guide from lubrication pipe and support rod.

CVT-227

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

14) Remove the lubrication pipe and support rod.

AT-05297

15) Detach the six claws to remove the two chain guide.

AT-05298

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

16) Remove the secondary pulley mounting bolt.

AT-05299

17) Remove the secondary pulley from drive pinion retainer and intersect the V groove of secondary pulley and V groove of primary pulley. Remove the variator chain from secondary pulley and remove the secondary pulley. CAUTION: Cover the V grooves of secondary pulley and primary pulley with cloth to protect the both pulleys and variator chain from scratching.

AT-05300

18) Remove the variator chain from primary pulley.

CVT-229

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

19) Remove the primary pulley mounting bolt.

AT-05301

20) Remove the primary pulley. 21) Remove the two seal rings from drive pinion retainer.

AT-05302

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

22) Remove the two seal rings from primary pulley.

AT-05493

B: INSTALLATION 1) Select shims for pulley alignment. 2) Install the two seal rings to drive pinion retainer. NOTE: • Use a new seal ring. • Apply CVTF to the seal rings. • When installing the seal ring, do not expand the seal ring too much.

AT-05302

3) Install the selected shims to the primary pulley bearing catch surface.

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

4) Install the two seal rings to primary pulley. NOTE: • Use a new seal ring. • Apply CVTF to the seal rings.

AT-05493

5) Install the primary pulley and adjust the position of bolt holes of primary bearing retainer and converter case to tighten the primary pulley bolt. NOTE: Use a new seal washer.

Tightening torque: 21 N·m (2.1 kgf-m, 15.5 ft-lb)

AT-05301

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

6) Set the ST to secondary pulley and expand the V groove of pulley. ST1 18769AA000 PULLEY EXPANDER

ST

AT-05303

7) Place the variator chain on the primary pulley groove and attach the secondary pulley and variator chain together to the drive pinion retainer. CAUTION: Cover the V grooves of primary pulley and secondary pulley with cloth to protect the both pulleys and variator chain from scratching. (1) Place the variator chain on primary pulley. (2) Intersect the V groove of primary pulley and the V groove of secondary pulley and install the secondary pulley while placing the variator chain on secondary pulley.

AT-05300

(3) While aligning the bolt hole of secondary bearing retainer and the bolt hole of driving pinion retainer, install the secondary pulley to drive pinion retainer.

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

8) Install the secondary pulley bolt.

Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb)

AT-05299

9) Install the chain guide. NOTE: Install it with two claws facing outward and with four claws facing inward.

AT-05298

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

10) Engage the cutout portions of support rod and drive pinion retainer and install the support rod.

AT-05304

11) Engage the cutout portions of lubrication pipe and drive pinion retainer and install the lubrication pipe.

AT-05305

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

12) Install the chain guide so that the lubrication pipe and support rod run through between the protrusions of each chain guide. Then remove the ST (PULLEY EXPANDER).

AT-05306

13) Install the O-ring to the lubrication pipe. NOTE: Use new O-rings. 14) Install the lubrication pipe.

AT-05345

15) Install the transmission case. 16) Install the forward clutch assembly. 17) Install the intermediate case. 18) Install the transfer reduction driven gear assembly. 19) Install the transfer clutch assembly. 20) Install the rear drive shaft. 21) Install the extension case. 22) Install the transmission harness. 23) Install the control valve body and oil pan. 24) Install the air breather hose.

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

25) Install the transmission assembly to the vehicle.

C: INSPECTION • • • •

Check the surface of primary and secondary pulley cones for damage or wear. Check the primary and secondary pulley for damage. Check the bearing for seizure or wear. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.

D: ADJUSTMENT 1. PROCEDURE IN REPLACEMENT OF PRIMARY AND SECONDARY PULLEY, OR IN REPLACEMENT OF PRIMARY PULLEY, SECONDARY PULLEY AND VARIATOR CHAIN 1) Measure depth “Lp” from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE

ST

Lp

AT-05346

2) Measure height “Ls” from the drive pinion retainer upper face to the secondary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE

ST

Ls

AT-05347

CVT-237

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

3) Calculate the following formula. Calculation formula: T (mm) = B + (Lp – Ls ) + 31.601 – A [T (in) = B + (Lp – Ls) + 1.224 – A] T: Pulley alignment A: Specified primary pulley dimension B: Specified secondary pulley dimension Lp: Depth from the ST upper face to the primary pulley bearing catch surface Ls: Depth from the ST upper face to the secondary pulley bearing catch surface 15 mm (0.591 in): Thickness of ST 31.601 mm (1.224 in): Constant Pulley alignment T mm (in) 0.050 — 0.150 (0.002 — 0.006) 0.151 — 0.250 (0.006 — 0.01) 0.251 — 0.350 (0.01 — 0.014) 0.351 — 0.450 (0.014 — 0.018) 0.451 — 0.550 (0.018 — 0.022) 0.551 — 0.650 (0.022 — 0.026) 0.651 — 0.750 (0.026 — 0.030) 0.751 — 0.850 (0.030 — 0.033) 0.851 — 0.950 (0.033 — 0.037)

Shim thickness mm (in) 0.1 (0.004) 0.2 (0.008) 0.3 (0.012) 0.4 (0.016) 0.5 (0.020) 0.6 (0.024) 0.7 (0.028) 0.8 (0.031) 0.9 (0.035)

4) Select one to two shims so that the total thickness meets the value obtained from step 3). Part number 32451AA000 32451AA010 32451AA020 32451AA030 32451AA040

Shim thickness mm (in) 0.1 (0.004) 0.2 (0.008) 0.3 (0.012) 0.4 (0.016) 0.5 (0.020)

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

2. PROCEDURE WHEN REPLACING ONLY DRIVE PINION RETAINER OR CONVERTER CASE 1) Clean the mating surface of current drive pinion retainer and converter case. 2) Measure and record the shim thickness that is attached on the current converter case. 3) Using the current drive pinion retainer, measure depth “Lp1” from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE

ST

Lp1

AT-05479

4) Using the current drive pinion retainer or current converter case, measure depth “Ls1” from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE

ST

Ls1

AT-05481

5) Calculate the “LD1” using the following formula and record it. Calculation formula: LD1 mm (in) = Lp1 – Ls1 LD1: Height from the primary pulley bearing catch surface to the secondary pulley bearing catch surface Lp1: Depth from the ST upper face to the primary pulley bearing catch surface Ls1: Depth from the ST upper face to the secondary pulley bearing catch surface

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

6) Using the new drive pinion retainer or new converter case, measure depth “Lp2” from the ST upper face to the primary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE

ST

Lp2

AT-05480

7) Using the new drive pinion retainer or new converter case, measure depth “Ls2” from the ST upper face to the secondary pulley bearing catch surface at several points and calculate the average. ST 499575400 GAUGE

ST

Ls2

AT-05482

8) Calculate the “LD2” using the following formula and record it. Calculation formula: LD2 mm (in) = Lp2 – Ls2 LD2: Height from the primary pulley bearing catch surface to the secondary pulley bearing catch surface Lp2: Depth from the ST upper face to the primary pulley bearing catch surface Ls2: Depth from the ST upper face to the secondary pulley bearing catch surface

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Primary Pulley and Secondary Pulley CONTINUOUSLY VARIABLE TRANSMISSION

9) Calculate the recorded values of “LD1” and “LD2” to obtain the positive number to select the shims. Calculation formula: T1 mm (in) = LD1 – LD2 or T2 mm (in) = LD2 – LD1 T1, T2: Difference between new drive pinion retainer or new converter case and current drive pinion retainer or current converter case LD1: Calculated value of current drive pinion retainer or current converter case LD2: Calculated value of new drive pinion retainer or new converter case Difference of the case (T1) mm (in) 0 — 0.020 (0 — 0.00078)

Shim selection procedure Select new shim of same thickness with the shim that is used on primary pulley side of the current converter case. 0.021 — 0.070 (0.000827 — 0.00275) Select new shim of same thickness with the shim that is used on primary pulley side of the current converter case. 0.071 — 0.125 (0.00279 — 0.00492) Select the shim of 0.1 mm thinner than the shim that is used on primary pulley side of the current converter case. 0.126 — 0.170 (0.00496 — 0.00669) Select the shim of 0.1 mm thinner than the shim that is used on primary pulley side of the current converter case. 0.171 — 0.230 (0.00673 — 0.00905) Select the shim of 0.2 mm thinner than the shim that is used on primary pulley side of the current converter case. 0.231 — 0.250 (0.00909 — 0.00984) Select the shim of 0.3 mm thinner than the shim that is used on primary pulley side of the current converter case. 0.251 — 0.300 (0.00988 — 0.01181) Select the shim of 0.3 mm thinner than the shim that is used on primary pulley side of the current converter case. Difference of the case (T2) mm (in) 0 — 0.020 (0 — 0.00078)

Shim selection procedure Select new shim of same thickness with the shim that is used on primary pulley side of the current converter case. 0.021 — 0.080 (0.000827 — 0.00315) Select new shim of same thickness with the shim that is used on primary pulley side of the current converter case. 0.081 — 0.100 (0.00318 — 0.00393) Select the shim of 0.1 mm thicker than the shim that is used on primary pulley side of the current converter case. 0.101 — 0.120 (0.00397 — 0.00472) Select the shim of 0.1 mm thicker than the shim that is used on primary pulley side of the current converter case. 0.121 — 0.180 (0.00476 — 0.00708) Select the shim of 0.1 mm thicker than the shim that is used on primary pulley side of the current converter case. 0.181 — 0.220 (0.00712 — 0.00866) Select the shim of 0.2 mm thicker than the shim that is used on primary pulley side of the current converter case. 0.221 — 0.280 (0.00870 — 0.01102) Select the shim of 0.2 mm thicker than the shim that is used on primary pulley side of the current converter case. 0.281 — 0.300 (0.01106 — 0.01181) Select the shim of 0.3 mm thicker than the shim that is used on primary pulley side of the current converter case. Part number 32451AA000 32451AA010 32451AA020 32451AA030 32451AA040

Shim thickness mm (in) 0.1 (0.004) 0.2 (0.008) 0.3 (0.012) 0.4 (0.016) 0.5 (0.020)

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Variator Chain CONTINUOUSLY VARIABLE TRANSMISSION

42.Variator Chain A: REMOVAL For removal of variator chain, refer to “Primary Pulley and Secondary Pulley”.

B: INSTALLATION For installation of variator chain, refer to “Primary Pulley and Secondary Pulley”.

C: INSPECTION Check the variator chain for damage and wear.

CVT-242

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

43.Drive Pinion Shaft Assembly A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the air breather hose. 3) Remove the oil pan and control valve body. 4) Remove the transmission harness. 5) Remove the extension case. 6) Remove the rear drive shaft. 7) Remove the transfer clutch assembly. 8) Remove the transfer reduction driven gear assembly. 9) Remove the intermediate case. 10) Remove the forward clutch assembly. 11) Remove the reduction driven gear. 12) Remove the transmission case. 13) Remove the primary pulley, secondary pulley and variator chain. 14) Using the ST, remove the drive pinion retainer and lubrication pipe. ST 18270KA020 SOCKET (E20)

AT-05348

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

15) Remove the O-ring.

AT-05350

16) Remove the oil pump.

AT-05349

CVT-244

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

17) Remove the O-ring.

AT-05351

B: INSTALLATION 1) Clean the mating surface of drive pinion retainer and converter case. 2) Adjust the backlash and tooth contact between drive pinion shaft assembly and the front differential side gear. 3) Install the O-ring for oil pump to drive pinion retainer. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

AT-05351

CVT-245

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

4) Install the oil pump. NOTE: Apply CVTF to the bolt.

Tightening torque: 8.5 N·m (0.9 kgf-m, 6.3 ft-lb)

AT-05349

5) Apply liquid gasket seamlessly to the mating surface of drive pinion retainer. NOTE: Be careful not to block the arrowed hole when applying liquid gasket.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

AT-05353

CVT-246

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

6) Install the O-ring to the lubrication pipe. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

AT-05354

7) Install the drive pinion retainer and lubrication pipe to converter case and tighten the bolt using the ST. ST 18270KA020 SOCKET (E20) NOTE: Do not confuse the three different-length bolts when installing.

Tightening torque: 43 N·m (4.4 kgf-m, 31.7 ft-lb)

(A)

(A)

(A)

(A)

(B)

(B) (C)

(B)

(A) (B) (C)

(C) (A) (B) (C) (A)

(C) AT-05355

8) Install the primary pulley, secondary pulley and variator chain. 9) Install the transmission case. 10) Install the forward clutch assembly. 11) Install the intermediate case. 12) Install the transfer reduction driven gear assembly.

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

13) Install the transfer clutch assembly. 14) Install the rear drive shaft. 15) Install the extension case. 16) Install the transmission harness. 17) Install the oil pan and control valve body. 18) Install the air breather hose. 19) Install the transmission assembly to the vehicle.

C: DISASSEMBLY 1) Remove the drive pinion assembly.

AT-05352

2) Flatten the tab of the lock nut. 3) Using ST1 and ST2, fix at the spline portion of drive pinion shaft to remove the lock nut. ST1 18621AA000 WRENCH ST2 18667AA010 HOLDER

ST1

ST2

AT-05356

CVT-248

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

4) Remove the taper roller bearing and outer race from drive pinion shaft.

AT-05357

5) Separate the front roller bearing from the drive pinion shaft using the ST. ST 498077000 REMOVER

ST

AT-05358

CVT-249

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

6) Remove the two oil seals using a screwdriver wrapped with cloth etc. CAUTION: Do not damage the fitting surface of drive pinion bearing.

AT-05359

7) Remove the plug from drive pinion retainer.

CVT-250

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

D: ASSEMBLY 1) Install the O-ring to plug and install the plug to drive pinion retainer. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) 2) Using the ST, install the oil seal to drive pinion retainer. NOTE: • Apply CVTF to the oil seal press-fitting surface and lip. • Install the oil seal in the correct direction. Pulley side ST 18657AA020 OIL SEAL INSTALLER ST

AT-05360

Front differential side ST 499277100 INSTALLER ST

AT-05361

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Measure the dimension “A” of drive pinion shaft. ST 398643600 GAUGE

A

AT-05362

4) Press-fit the new inner bearing inner race using the ST. ST 499277200 INSTALLER

ST

AT-05363

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

5) Press-fit the new outer bearing outer race and inner bearing inner race. CAUTION: Damage may result if too much force is applied to the roller bearing. NOTE: Press in to a position where the bearing rotates smoothly without play.

AT-05364

6) Tighten a new lock nut using the ST. Using the following formula, calculate the torque for a torque wrench. T2 = L2/(L1 + L2) × T1 T1: 130 N·m (13.3 kgf-m, 95.9 ft-lb) [Required torque setting] T2: Tightening torque L1: ST1 length 0.1 m (3.94 in) L2: Torque wrench length Example: Torque wrench length m (in) 0.4 (15.75)

Tightening torque N·m (kgf-m, ft-lb) 104 (10.6, 76.7)

0.45 (17.72) 0.5 (19.69) 0.55 (21.65)

106 (10.8, 78.2) 108 (11.0, 79.7) 110 (11.2, 81.1)

ST1 ST2

18621AA000 18667AA010

WRENCH HOLDER

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

NOTE: Tighten the lock nut while directly aligning ST1 and torque wrench.

ST1

ST2

AT-05356

7) Apply differential gear oil to roller of bearing and rotate the bearing several times. 8) Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If the torque is not within specified range, replace the roller bearing.

Starting torque: 11.6 — 34.7 N (1.2 — 3.5 kgf, 2.6 — 7.8 lb)

AT-05365

9) Crimp the lock nut in 2 locations.

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

10) Measure the dimension “B” of the drive pinion shaft. ST 398643600 GAUGE

ST

B AT-05366

11) Obtain thickness “t” mm (in) of the drive pinion shim. t = 6.55±0.1225 – (B – A) 12) Select three or less shims from following table. Part number 31451AA050 31451AA060 31451AA070 31451AA080 31451AA090 31451AA100 31451AA240

Drive pinion shim Thickness mm (in) 0.150 (0.0059) 0.175 (0.0069) 0.200 (0.0079) 0.225 (0.0089) 0.250 (0.0098) 0.275 (0.0108) 0.300 (0.0118)

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

13) Install the shims selected for drive pinion retainer and drive pinion shaft assembly. NOTE: Be careful not to bend the shim.

Tightening torque: 70 N·m (7.1 kgf-m, 51.6 ft-lb)

AT-05352

E: INSPECTION • Make sure that all component parts are free of scratches, holes and other faults. • Check the tooth contact. • Check the bearing preload of drive pinion shaft. CAUTION: Before measuring, apply differential gear oil to roller of bearing and rotate the bearing several times.

Starting torque: 11.6 — 34.7 N (1.2 — 3.5 kgf, 2.6 — 7.8 lb)

AT-05365

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

F: ADJUSTMENT 1) Remove the liquid gasket from the mating surface completely. 2) Using the ST, install the drive pinion retainer to converter case. ST1 18270KA020 SOCKET (E20) NOTE: Do not confuse the three different-length bolts when installing.

Tightening torque: 43 N·m (4.4 kgf-m, 31.7 ft-lb)

(A)

(A)

(A)

(A)

(B)

(B) (C)

(B)

(A) (B) (C)

(C) (A) (B) (C) (A)

(C) AT-05355

3) Rotate the drive pinion several times using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 WRENCH

ST2 ST1

AT-05394

4) Adjust the drive pinion and hypoid driven gear backlash. 5) Using the ST, remove the drive pinion retainer from converter case. ST1 18270KA020 SOCKET (E20)

CVT-257

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

6) Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Then install the drive pinion retainer and rotate the drive pinion in both directions several times. Remove the drive pinion retainer and check the tooth contact pattern. If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. NOTE: After correction, wipe off the lead-free red dye. • Correct tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.

(A)

(B)

AT-05367

(A) Toe side (B) Heel side

CVT-258

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

• Face contact Check item: Backlash is too large. Contact pattern

AT-05368

Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.

AT-05369

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

• Flank contact Check item: Backlash is too small. Contact pattern

AT-05370

Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.

AT-05371

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

• Toe contact (inside contact) Check item: Teeth contact area is too small. Contact pattern

AT-05372

Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear side.

AT-05371

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

• Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern

AT-05373

Corrective action: Increase thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the hypoid driven gear.

AT-05369

7) If tooth contact is correct, mark the differential side retainer position and loosen. After fitting a new O-ring and oil seal, screw in the differential side retainer to the marked position.

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Drive Pinion Shaft Assembly CONTINUOUSLY VARIABLE TRANSMISSION

8) Tighten the lock plate with specified torque.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

(A)

AT-05400

(A) Lock plate

CVT-263

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

44.Front Differential Assembly A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the air breather hose. 3) Remove the oil pan and control valve body. 4) Remove the transmission harness. 5) Remove the extension case. 6) Remove the rear drive shaft. 7) Remove the transfer clutch assembly. 8) Remove the transfer reduction driven gear assembly. 9) Remove the intermediate case. 10) Remove the forward clutch assembly. 11) Remove the reduction driven gear. 12) Remove the transmission case. 13) Remove the primary pulley, secondary pulley and variator chain. 14) Remove the drive pinion shaft assembly. 15) Remove the lock plates on both sides.

(A)

AT-05400

(A) Lock plate

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

16) Remove the differential side retainers using ST. ST 18658AA020 WRENCH COMPL RETAINER NOTE: • Support the differential case assembly by hand to avoid damaging the retainer mounting hole of the converter case. • When keeping the retainers aside, use labels etc. to avoid confusing the left and right.

ST

AT-05375

17) Remove the front differential assembly while being careful not to damage the attachment part of the retainer. 18) Remove the oil seals and O-rings from both differential side retainers.

B: INSTALLATION 1) Install the front differential assembly to the converter case. NOTE: Be careful not to damage the inside of the case (especially the mating surface of the differential side retainers). 2) Temporarily install the differential side retainers using ST. ST 18658AA020 WRENCH COMPL RETAINER

ST

AT-05375

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Adjust the backlash of the front differential. 4) Inspect and adjust the tooth contact. 5) Remove the differential side retainers and install the O-rings and oil seals. NOTE: • Record how many turns were needed to remove. • Use new O-rings and oil seals. 6) Install the differential side retainers using ST. NOTE: When attaching, turn the differential side retainer by the same number of turns it took to remove, and align the marks. ST 18658AA020 WRENCH COMPL RETAINER 7) Install the lock plate.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

(A)

AT-05400

(A) Lock plate

8) Install the drive pinion shaft assembly. 9) Install the primary pulley, secondary pulley and variator chain. 10) Install the transmission case. 11) Install the forward clutch assembly. 12) Install the intermediate case. 13) Install the transfer reduction driven gear assembly. 14) Install the transfer clutch assembly. 15) Install the rear drive shaft. 16) Install the extension case. 17) Install the transmission harness. 18) Install the control valve body and oil pan. 19) Install the air breather hose. 20) Install the transmission assembly to the vehicle.

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

C: DISASSEMBLY 1. DIFFERENTIAL CASE ASSEMBLY 1) Remove the taper roller bearing using the ST. ST 498077000 REMOVER

ST

ST

AT-05376

2) Remove the hypoid driven gear mounting bolt using the ST. ST 18270KA020 SOCKET (E20)

AT-05377

CVT-267

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Remove the differential case (LH).

AT-05378

4) Remove the differential bevel gear and washer from differential case.

AT-05379

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

5) Remove the straight pin.

AT-05380

6) Remove the pinion shaft, then remove the differential bevel gear, washer and differential bevel pinion.

(B)

(C)

(C)

(A) AT-05381

(A) Pinion shaft (B) Differential bevel gear (C) Differential bevel pinion

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

2. SIDE RETAINER NOTE: After adjusting the drive pinion backlash and tooth contact, replace the oil seal and O-ring with new parts. 1) Remove the O-ring.

AT-05382

2) Remove the oil seal.

AT-05383

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Remove the split pin (ST), and then remove the claw. ST 398527700 PULLER ASSY

(C)

(A)

(B)

AT-05384

(A) Claw (B) Split pin (C) Pin

4) Attach two claws to the outer race, and set the ST to side retainer. ST 398527700 PULLER ASSY

(B)

(A)

AT-05386

(A) Shaft (B) Claw

5) Restore the removed claws to original position, and install the pin and split pin.

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

6) Hold the shaft of ST to avoid removing from side retainer, and then remove the bearing outer race. ST 398527700 PULLER ASSY NOTE: Replace the bearing inner and outer races as a single unit.

(A) (A)

(B)

AT-05385

(A) Shaft (B) Side retainer

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

D: ASSEMBLY 1. DIFFERENTIAL CASE ASSY 1) Install the washer and differential bevel gear into differential case (LH).

AT-05388

2) Install the differential bevel gear pinions into differential case (LH) and install the pinion shaft.

(B)

(C)

(C)

(A) AT-05381

(A) Pinion shaft (B) Differential bevel gear (C) Differential bevel pinion

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Install the straight pin.

AT-05387

4) Install the differential case (RH) to hypoid driven gear and secure with vise.

AT-05389

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

5) Install the washer and differential bevel gear to the differential case (RH).

AT-05379

6) Using the ST, install the hypoid driven gear by tightening the installation bolt. ST 18270KA020 SOCKET (E20)

Tightening torque: 69 N·m (7.0 kgf-m, 50.9 ft-lb)

AT-05377

7) Measurement of backlash (Selection of washer) (1) Install the SUBARU genuine axle shaft to differential case. Part No. 38415AA070 Axle shaft (2) Measure the gear backlash using ST1 and ST2, and then insert the ST2 through the window of differential case. ST1 498247001 MAGNET BASE ST2 498247100 Dial gauge NOTE: • Measure the backlash by applying a differential bevel pinion tooth between two differential bevel gear teeth. • When measuring, fix the differential bevel pinion gear in place with a screwdriver covered with waste cloth, or a similar tool.

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

Specification: 0.13 — 0.18 mm (0.0051 — 0.0071 in)

ST2

ST1

AT-05390

(3) If the backlash is not within specification, select a washer from the table below and replace. Washer Part number 803038021 803038022 803038023

Thickness mm (in) 0.95 (0.037) 1.00 (0.039) 1.05 (0.041)

8) Using the ST, install the left and right taper roller bearings. ST1 499277100 BUSHING 1-2 INSTALLER ST2 398497701 SEAT ST1

ST2

CVT-276

AT-05391

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

2. SIDE RETAINER NOTE: After adjusting the backlash and tooth contact, replace the oil seal and O-ring of side retainer with new parts. 1) Press-fit the bearing outer race to side retainer. 2) Using the ST, install the oil seal. NOTE: • Use a new oil seal. • Apply differential oil to the oil seal lip. • Oil seal has an identification mark (R, L). When installing oil seals, do not confuse the left and right. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER

AT-05392

3) Install the O-ring. NOTE: Use new O-rings.

AT-05382

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

E: INSPECTION • Check each component for scratches, damage or other faults. • Inspect the backlash of the pinion gear.

Specification: 0.13 — 0.18 mm (0.0051 — 0.0071 in)

ST2

ST1

AT-05390

• Measure the hypoid gear backlash, and then adjust it to be within specification.

F: ADJUSTMENT 1) Using the ST, screw-in the retainer until resistance is felt. NOTE: RH side should be screwed-in more than LH side. ST 18658AA020 WRENCH COMPL RETAINER

ST

AT-05375

2) Remove the remaining liquid gasket from the mating surface completely.

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

3) Using the ST, install the drive pinion assembly to converter case. ST1 18270KA020 SOCKET (E20) NOTE: Do not confuse the three different-length bolts when installing.

Tightening torque: 43 N·m (4.4 kgf-m, 31.7 ft-lb)

(A)

(A)

(A)

(A)

(B)

(B) (C)

(B)

(A) (B) (C)

(C) (A) (B) (C) (A)

(C) AT-05355

4) Rotate the drive pinion shaft more than ten times using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 Wrench

ST2 ST1

AT-05394

5) While rotating the pinion shaft, keep tightening the retainer LH, and loosening the retainer RH until the pinion shaft no longer be turned. When pinion shaft no longer turns, backlash is “zero”.

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

6) After the “zero” state is established, loosen the retainer LH by 3 notches and secure it with the lock plate. Loosen the retainer RH and retighten until it stops. Rotate the drive pinion 2 or 3 times. Tighten the retainer RH further 1-3/4 notches. This sets the preload. Finally, secure the retainer with its lock plate.

(A)

AT-05400

(A) Lock plate

NOTE: Turning the retainer by every one tooth changes the backlash approx. 0.05 mm (0.0020 in).

(A)

AT-05401

(A) 1 tooth

7) Insert the two Subaru genuine axle shaft into differential case. Part No. 38415AA070 Axle shaft

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Front Differential Assembly CONTINUOUSLY VARIABLE TRANSMISSION

8) Wrap the drive shaft pinion shaft with cloth and pinch with vise pliers. Install the installation bolt into the bolt hole of secondary pulley and secure the bolt and vise pliers using a band or wire. Make sure the drive pinion shaft does not move.

AT-05620

9) Check the backlash is within specification using ST1, ST2 and ST3. ST1 498255400 PLATE ST2 498247100 DIAL GAUGE ST3 498247001 MAGNET BASE

Backlash: 0.13 — 0.18 mm (0.005 — 0.007 in) ST1

ST2

ST3

AT-05402

10) Adjust the teeth contact of the front differential and drive shaft.

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Oil Pump CONTINUOUSLY VARIABLE TRANSMISSION

45.Oil Pump A: REMOVAL NOTE: Refer to “Drive Pinion Shaft” for removal procedures.

B: INSTALLATION NOTE: Refer to “Drive Pinion Shaft” for removal procedures.

C: INSPECTION Check the following items. • Check the oil pump for damage and wear. • Rotate the oil pump by hand, and check that it rotates smoothly. 1) Measure the secondary pressure. 2) Remove the oil pan and oil strainer. 3) Check oil strainer for clogging. When oil strainer has no clogging, replace the oil pump.

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Oil Pump Chain CONTINUOUSLY VARIABLE TRANSMISSION

46.Oil Pump Chain A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the torque converter assembly. 3) Remove the oil pump chain cover.

AT-05403

4) Remove the seal ring from center support COMPL.

AT-05414

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Oil Pump Chain CONTINUOUSLY VARIABLE TRANSMISSION

5) Remove the driven sprocket from oil pump chain cover to remove the oil pump chain. NOTE: The driven sprocket is replaced as an assembly only, because it is a non-disassembly part.

AT-05404

6) Remove the snap ring.

AT-05405

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Oil Pump Chain CONTINUOUSLY VARIABLE TRANSMISSION

7) Remove the drive sprocket.

AT-05406

8) Remove the oil seal from the oil pump chain cover.

B: INSTALLATION 1) Clean the mating surface of oil pump chain cover and converter case cover. 2) Using the ST, install the oil seal. ST 499755602 PRESS SNAP RING

ST

AT-05407

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Oil Pump Chain CONTINUOUSLY VARIABLE TRANSMISSION

3) Install the drive sprocket and install the snap ring.

AT-05405

4) Place the oil pump chain on drive sprocket. 5) Place the oil pump chain on driven sprocket and install the driven sprocket to oil pump chain cover.

AT-05408

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Oil Pump Chain CONTINUOUSLY VARIABLE TRANSMISSION

6) Install the seal ring to center support COMPL. NOTE: • Use a new seal ring. • Apply CVTF to the seal rings.

AT-05414

7) Apply liquid gasket seamlessly to the mating surface of oil pump chain cover. CAUTION: Do not apply liquid gasket at the arrowed hole.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

AT-05409

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Oil Pump Chain CONTINUOUSLY VARIABLE TRANSMISSION

8) Install the oil pump chain cover. NOTE: • There are two types of bolt. • Following the transmission serial number, replace the bolt (A) with a new part or reuse it. #169460 or earlier: Use a new micro-encapsulated bolt. #169461 — #173616: Use a new micro-encapsulated bolt or normal bolt. #173617 or later: The bolt can be reused.

Tightening torque: 24 N·m (2.4 kgf-m, 17.7 ft-lb)

(A)

(B) (B) (A)

(A)

(B)

(B)

(B) (B) AT-05410

9) Install the torque converter assembly. 10) Install the transmission assembly to the vehicle.

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Oil Pump Chain CONTINUOUSLY VARIABLE TRANSMISSION

C: DISASSEMBLY 1. DRIVE SPROCKET 1) Remove the ball bearing using ST. ST1 498077600 REMOVER ST2 399513600 INSTALLER

ST2

ST1

AT-05411

D: ASSEMBLY 1. DRIVE SPROCKET 1) Using the ST, install the ball bearing. NOTE: Use a new ball bearing. ST 499755602 PRESS SNAP RING

ST

AT-05412

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Oil Pump Chain CONTINUOUSLY VARIABLE TRANSMISSION

E: INSPECTION • • • • • • •

Check the oil pump chain for damage. Replace if gear teeth are broken, damaged, sharpen or excessively worn. Check the bearing for seizure or wear. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc. Check the oil pump chain cover for damage. Check for leakage of CVTF from the mating surface of oil pump chain cover. Check the oil seal for damage.

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Converter Case Cover CONTINUOUSLY VARIABLE TRANSMISSION

47.Converter Case Cover A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the air breather hose. 3) Remove the oil pan and control valve body. 4) Remove the transmission harness. 5) Remove the extension case. 6) Remove the rear drive shaft. 7) Remove the transfer clutch assembly. 8) Remove the transfer reduction driven gear assembly. 9) Remove the intermediate case. 10) Remove the forward clutch assembly. 11) Remove the reduction driven gear. 12) Remove the transmission case. 13) Remove the primary pulley, secondary pulley and variator chain. 14) Remove the drive pinion shaft assembly. 15) Remove the oil stopper plate and lubrication pipe.

AT-05447

16) Flip over the converter case.

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Converter Case Cover CONTINUOUSLY VARIABLE TRANSMISSION

17) Remove the converter case cover.

AT-05418

18) Remove the O-ring.

AT-05419

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Converter Case Cover CONTINUOUSLY VARIABLE TRANSMISSION

19) Remove the seal ring from converter case cover.

AT-05420

B: INSTALLATION 1) Clean the mating surface of converter case cover and converter case. 2) Adjust the shims of front reduction drive gear and front reduction driven gear. 3) Install the O-ring. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

AT-05419

4) Apply CVTF to the selected shims and install each to the catch surface of bearing.

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Converter Case Cover CONTINUOUSLY VARIABLE TRANSMISSION

5) Install the seal ring to converter case cover. NOTE: • Use a new seal ring. • When installing the seal ring, do not expand the seal ring too much.

AT-05420

6) Apply liquid gasket seamlessly to the mating surface of converter case cover.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

AT-05421

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Converter Case Cover CONTINUOUSLY VARIABLE TRANSMISSION

7) Install the converter case cover.

Tightening torque: 24 N·m (2.4 kgf-m, 17.7 ft-lb)

AT-05418

8) Flip over the converter case cover. 9) Install the oil stopper plate and lubrication pipe.

Tightening torque: 9 N·m (0.9 kgf-m, 6.6 ft-lb)

AT-05447

10) Install the drive pinion shaft assembly. 11) Install the primary pulley, secondary pulley and variator chain. 12) Install the transmission case. 13) Install the forward clutch assembly. 14) Install the intermediate case. 15) Install the transfer reduction driven gear assembly. 16) Install the transfer clutch assembly.

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Converter Case Cover CONTINUOUSLY VARIABLE TRANSMISSION

17) Install the rear drive shaft. 18) Install the extension case. 19) Install the transmission harness. 20) Install the control valve body and oil pan. 21) Install the air breather hose. 22) Install the transmission assembly to the vehicle.

C: DISASSEMBLY 1) Remove the oil pump chain cover. 2) Using TORX® E16, remove the center support COMPL.

AT-05422

3) Remove the plug and O-ring.

AT-05423

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Converter Case Cover CONTINUOUSLY VARIABLE TRANSMISSION

D: ASSEMBLY 1) Install the plugs. NOTE: • Use new O-rings. • Apply CVTF to the O-ring.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-05423

2) Using

TORX®

E16, install the center support COMPL.

Tightening torque: 21.5 N·m (2.2 kgf-m, 15.9 ft-lb)

AT-05422

3) Install the oil pump chain cover.

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Converter Case Cover CONTINUOUSLY VARIABLE TRANSMISSION

E: INSPECTION • Replace if its tooth surfaces are broken, damaged or excessively worn. • Check the bearing for seizure or wear. • Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.

F: ADJUSTMENT When replacing the converter case cover, select the following shims. • Select the shim for front reduction drive gear. • Select the shim for front reduction driven gear.

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Front Reduction Drive Gear CONTINUOUSLY VARIABLE TRANSMISSION

48.Front Reduction Drive Gear A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the air breather hose. 3) Remove the oil pan and control valve body. 4) Remove the transmission harness. 5) Remove the primary speed sensor. 6) Remove the extension case. 7) Remove the rear drive shaft. 8) Remove the transfer clutch assembly. 9) Remove the transfer reduction driven gear assembly. 10) Remove the intermediate case. 11) Remove the forward clutch assembly. 12) Remove the reduction driven gear. 13) Remove the transmission case. 14) Remove the primary pulley, secondary pulley and variator chain. 15) Remove the drive pinion shaft assembly. 16) Remove the converter case cover. 17) Remove the front reduction drive gear and front reduction driven gear together.

AT-05424

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Front Reduction Drive Gear CONTINUOUSLY VARIABLE TRANSMISSION

18) Remove the seal ring.

AT-05420

B: INSTALLATION 1) Clean the mating surface of converter case cover and converter case. 2) Select the shim for front reduction drive gear. 3) Install the front reduction drive gear and front reduction driven gear together.

AT-05424

4) Install the converter case cover. 5) Install the drive pinion shaft assembly. 6) Install the primary pulley, secondary pulley and variator chain. 7) Install the transmission case. 8) Install the forward clutch assembly. 9) Install the intermediate case. 10) Install the transfer reduction driven gear assembly. 11) Install the transfer clutch assembly. 12) Install the rear drive shaft.

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Front Reduction Drive Gear CONTINUOUSLY VARIABLE TRANSMISSION

13) Install the extension case. 14) Install the primary speed sensor. 15) Install the transmission harness. 16) Install the control valve body and oil pan. 17) Install the air breather hose. 18) Install the transmission assembly to the vehicle.

C: DISASSEMBLY 1) Remove the seal ring and O-ring.

AT-05429

2) Using the ST, remove the ball bearing from front reduction drive gear. ST 899864100 REMOVER

ST

AT-05425

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Front Reduction Drive Gear CONTINUOUSLY VARIABLE TRANSMISSION

3) Using the ST, remove the ball bearing from front reduction drive gear. ST 498077000 REMOVER

ST

AT-05426

D: ASSEMBLY 1) Using the ST, install the ball bearing to front reduction drive gear. NOTE: Use a new ball bearing. ST 18651AA000 INSTALLER

ST

AT-05427

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Front Reduction Drive Gear CONTINUOUSLY VARIABLE TRANSMISSION

2) Using ST1 and ST2, install the ball bearing to front reduction drive gear. NOTE: Use a new ball bearing. ST1 499757002 PRESS SNAP RING ST2 398177700 INSTALLER

ST1

ST2

AT-05428

3) Install the seal ring. NOTE: • Use a new seal ring. • When installing the seal ring, do not expand the seal ring too much. • Install the O-ring when installing the torque converter assembly.

AT-05430

E: INSPECTION • Replace if its tooth surfaces are broken, damaged or excessively worn. • Check the bearing for seizure or wear. • Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.

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Front Reduction Drive Gear CONTINUOUSLY VARIABLE TRANSMISSION

F: ADJUSTMENT 1) Measure height “A” from the ST upper face to the bearing end face using the ST. ST 398643600 GAUGE ST

ST

A

AT-05431

2) Measure depth “B” from the converter case cover upper face to the bearing catch surface.

B

AT-05432

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Front Reduction Drive Gear CONTINUOUSLY VARIABLE TRANSMISSION

3) Using the ST, measure height “C” from the ST upper face to the converter case cover mating surface. ST 398643600 GAUGE ST ST

C

AT-05433

4) Calculate clearance “T” using the following formula. Calculation formula: T mm = (A – 15) – ((C – 15) – B) [T in = (A – 0.591) – ((C – 0.591) – B)] T: Clearance A: Depth from the ST upper face to the bearing end surface B: Depth from the converter case cover upper face to the bearing catch surface C: Height from the ST upper face to the converter case cover mating surface 15 mm (0.591 in): Thickness of ST Clearance “T” mm (in)

Thickness of shim mm (in)

Part number

1.070 — 1.174 (0.042 — 0.045) 1.175 — 1.274 (0.046 — 0.049) 1.275 — 1.374 (0.050 — 0.053) 1.375 — 1.474 (0.054 — 0.057) 1.475 — 1.580 (0.058 — 0.062)

1.0 (0.039) 1.1 (0.043) 1.2 (0.047) 1.3 (0.051) 1.4 (0.055)

31288AA160 31288AA170 31288AA180 31288AA220 31288AA230

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Front Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

49.Front Reduction Driven Gear A: REMOVAL NOTE: For removal of front reduction driven gear, refer to the “Front Reduction Drive Gear”.

B: INSTALLATION NOTE: For installation of front reduction driven gear, refer to the “Front Reduction Drive Gear”.

C: DISASSEMBLY 1) Using the ST, remove the ball bearing, front reduction driven gear and front reduction driven shaft. ST1 899864100 REMOVER ST2 18767AA000 BEARING REMOVER

ST2

ST1

AT-05434

2) Remove the snap ring.

AT-05435

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Front Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

3) Remove the retaining plate, drive plate, driven plate and dish plate.

AT-05436

4) Remove the seal ring from front reduction driven shaft.

AT-05437

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Front Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

5) Using the round bar with diameter of 7 mm (0.28 in), tap the entire circumference around the ball bearing outer race a little at a time through the front reduction driven shaft hole, to remove the ball bearing.

AT-05678

D: ASSEMBLY 1) Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table. NOTE: Make sure of the direction of dish plate. 2) Set the dial gauge to retaining plate, and read its scale. NOTE: The value, which is read in the gauge at this time, is zero point. 3) Scale and record the weight “Z” of a flat board which will be put on retaining plate. NOTE: • Use a stiff board which does not bend against load as a flat board to be put on retaining plate. • Use a flat board weighing less than 130 N (13.3 kgf, 29.2 lb). 4) Put the flat board on retaining plate.

AT-05234

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Front Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

5) Using the following formula, calculate load “N”, a force of pressing with push/pull gauge. N = 130 N (13.3 kgf, 29.2 lb) – Z 130 N (13.3 kgf, 29.2 lb) : Load applied to clutch plate Z: Flat board weight 6) Press the center of retaining plate by applying a force of “N” using push/pull gauge, and then measure and record the compression amount “A”. NOTE: Measure at four points with a 90° interval and calculate the average.

A

(C)

(A) (B) (D)

AT-05587

(A) (B) (C) (D)

Drive plate Driven plate Retaining plate Dish plate

7) Install the dish plate, driven plate, drive plate, retaining plate and snap ring. NOTE: Make sure of the direction of dish plate.

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Front Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

8) Measure and record the clearance “B” between the retaining plate and snap ring. NOTE: Before measuring, press down the whole circumference of retaining plate using your finger.

B

AT-05439

9) Piston stroke calculation Calculate with A and B dimensions recorded before. If out of standard, replace with a new drive plate and adjust it within standard. S mm (in) = A + B S: Piston stroke A: Compression amount of drive plate and dish plate B: Clearance between retaining plate and snap ring

Specification: 2.4 — 2.8 mm (0.094 — 0.11 in) Part number 31667AB430 31667AB440 31667AB450

Retaining plate Thickness mm (in) 3.1 (0.122) 3.3 (0.130) 3.5 (0.138)

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Front Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

10) Press-fit the ball bearing into front driven shaft. NOTE: Use a new ball bearing.

AT-05440

11) Install the seal ring to the front driven shaft. NOTE: • Install a new seal ring. • Apply CVTF to the seal rings.

AT-05437

12) Install the front driven shaft to front driven gear.

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Front Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

13) Using the ST, install the ball bearing. NOTE: Use a new ball bearing. ST 18651AA000 INSTALLER ST

AT-05444

14) Install the front reduction driven gear assembly to converter case cover.

AT-05445

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Front Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

15) Apply compressed air intermittently to check the piston operation. NOTE: Hold the arrowed area with a finger.

AT-05446

E: INSPECTION • • • • • •

Check the drive plate for wear and damage. Check the driven plate for discoloration (burnt color). Check for worn snap ring, fatigue or damaged return spring or deformed piston retainer. Replace if its tooth surfaces are broken, damaged or excessively worn. Check the bearing for seizure or wear. Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.

F: ADJUSTMENT 1) Using the ST, measure height “A” from the ST upper face to the mating surface of the case. ST 398643600 GAUGE

ST

ST

A

AT-05442

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Front Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

2) Measure depth “B” from the converter case cover upper face to the bearing catch surface.

B

AT-05441

3) Measure depth “C” from the ST upper face to the bearing end face using the ST. ST 398643600 GAUGE

ST

ST

C

AT-05443

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Front Reduction Driven Gear CONTINUOUSLY VARIABLE TRANSMISSION

4) Using the following formula, calculate clearance “T” to select a shim. Formula: T mm = (C – 15) – ((A – 15) – B) [T in = (C – 0.591) – ((A – 0.591) – B)] T: Clearance A: Height from the ST upper face to the converter case mating surface B: Depth from the converter case cover upper face to the bearing catch surface C: Depth from the ST upper face to the bearing end face 15 mm (0.591 in): Thickness of ST Clearance “T” mm (in) 0.470 — 0.569 (0.019 — 0.021) 0.570 — 0.669 (0.022 — 0.025) 0.670 — 0.769 (0.026 — 0.029) 0.770 — 0.869 (0.030 — 0.033) 0.870 — 0.980 (0.034 — 0.039)

Thickness of shim mm (in) 0.4 0.5 0.6 0.7 0.8

5) Select one to two shims so that the total thickness meets the value obtained from above. Part number 31288AA130 31288AA140 31288AA150

Thickness of shim mm (in) 0.2 0.3 0.5

CVT-315

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Converter Case CONTINUOUSLY VARIABLE TRANSMISSION

50.Converter Case A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the air breather hose. 3) Remove the oil pan and control valve body. 4) Remove the transmission harness. 5) Remove the secondary pressure sensor. 6) Remove the primary speed sensor. 7) Remove the extension case. 8) Remove the rear drive shaft. 9) Remove the transfer clutch assembly. 10) Remove the transfer reduction driven gear assembly. 11) Remove the intermediate case. 12) Remove the forward clutch assembly. 13) Remove the reduction driven gear. 14) Remove the transmission case. 15) Remove the primary pulley, secondary pulley and variator chain. 16) Remove the drive pinion shaft assembly. 17) Remove the front differential assembly. 18) Remove the converter case cover. 19) Remove the front reduction drive gear and front reduction driven gear.

B: INSTALLATION 1) Install the front reduction drive gear and front reduction driven gear. 2) Install the converter case cover. 3) Install the front differential assembly. 4) Install the drive pinion shaft assembly. 5) Install the primary pulley, secondary pulley and steel chain. 6) Install the transmission case. 7) Install the reduction driven gear. 8) Install the forward clutch assembly. 9) Install the intermediate case. 10) Install the transfer reduction driven gear. 11) Install the transfer clutch assembly. 12) Install the rear drive shaft. 13) Install the extension case. 14) Install the primary speed sensor. 15) Install the secondary pressure sensor. 16) Install the transmission harness. 17) Install the control valve body and oil pan. 18) Install the air breather hose. 19) Install the transmission assembly to the vehicle.

CVT-316

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Converter Case CONTINUOUSLY VARIABLE TRANSMISSION

C: DISASSEMBLY 1) Remove the transmission hanger and transmission radio ground cord. 2) Remove the oil drain plug and overflow drain plug. 3) Remove all plugs.

AT-05448

D: ASSEMBLY 1) Install the oil drain plug and overflow drain plug. NOTE: Overflow plug of differential gear oil is temporarily attached. 2) Install all plugs. NOTE: Use new O-rings.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-05448

CVT-317

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Converter Case CONTINUOUSLY VARIABLE TRANSMISSION

3) Install the transmission hanger and transmission radio ground cord.

Tightening torque: 41 N·m (4.2 kgf-m, 30.2 ft-lb)

(A)

AT-05647

(A) Install within the range of 30° approximately.

E: INSPECTION • Check for leakage of CVTF from the connection between converter case and transmission case. • Check there is no damage or cracks on the converter case.

F: ADJUSTMENT When replacing the converter case cover, select the following shims. • Select the shim for front reduction drive gear. • Select the shim for front reduction driven gear. • Select shims for primary pulley.

CVT-318

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Diagnostics with Phenomenon CONTINUOUSLY VARIABLE TRANSMISSION

51.Diagnostics with Phenomenon A: INSPECTION Symptoms Stall speed is low after warming-up, with select lever in “D” or “R” range.

Vehicle does not move despite engine speed rising up, with select lever in “D” or “R” range.

Vehicle does not move by engine stall, with select lever in “D” or “R” range. Excessive shock occurs at starting, with select lever in “D” or “R” range. Acceleration speed from standstill is insufficient, with select lever in “D” or “R” range. Engine speed suddenly rises up during driving, with select lever in “D” or “R” range.

Vibration occurs during driving, with select lever in “D” or “R” range.

Sudden braking occurs during driving, with select lever in “D” or “R” range. During deceleration, lockup clutch does not disengage until just before halting, with select lever in “D” or “R” range. Engine stalls with vehicle at a standstill, with select lever in “D” or “R” range. Excessive lockup shock occurs during driving, with select lever in “D” range.

Faulty parts Engine control system • • • • • • • • • • • • • • • • • • • •

Engine control system Select cable CVTF Secondary pressure circuit Pulley, gear and variator chain Forward/reverse changeover section TCM Control valve body Inhibitor switch Parking mechanism Select cable Bearing Forward/reverse changeover section Secondary pressure circuit Pulley, gear and variator chain Control valve body Forward/reverse changeover section Control valve body Secondary pressure circuit Primary pressure circuit

• Secondary pressure circuit • Primary pressure circuit • Forward/reverse changeover section • Pulley and variator chain • Torque converter ASSY • Hydraulic pressure circuit to torque converter • Control valve body • Secondary pressure circuit • Primary pressure circuit • Control valve body Control valve body • Engine control system • Control valve body Control valve body

Slipping occurs at lockup, or lockup does not occur during driving, with select lever in “D” range.

• Control valve body • Lockup hydraulic line • Torque converter ASSY

Excessive shifting shock occurs when shifting the select lever from “N” range to “D” range, or from “N” range to “R” range.

• Inhibitor switch • Control valve body • Forward/reverse changeover section

Vehicle does not keep at standstill with select lever in “P” range, or parking cannot be released when shifting from “P” range to another range. Select lever does not shift smoothly.

• Select cable • Parking mechanism • • • •

Select cable Inhibitor switch Detent spring Manual plate

CVT-319

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Diagnostics with Phenomenon CONTINUOUSLY VARIABLE TRANSMISSION

CVT-320

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CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

CVT(diag) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Page Basic Diagnostic Procedure .......................................................................2 Check List for Interview ..............................................................................4 General Description ...................................................................................5 Electrical Component Location ..................................................................7 Transmission Control Module (TCM) I/O Signal ......................................11 Subaru Select Monitor ..............................................................................15 Read Current Data ...................................................................................16 Read Diagnostic Trouble Code (DTC) .....................................................17 Clear Memory Mode .................................................................................18 Inspection Mode .......................................................................................19 Learning Control .......................................................................................20 AT OIL TEMP Warning Light Display .......................................................22 AWD Warning Light Display .....................................................................25 Diagnostic Procedure for Subaru Select Monitor Communication ...........28 List of Diagnostic Trouble Code (DTC) ....................................................32 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................35 Diagnostic Procedure without Diagnostic Trouble Code (DTC) ...............90 Diagnostics with Phenomenon .................................................................91

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Basic Diagnostic Procedure CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

1. Basic Diagnostic Procedure A: PROCEDURE 1

2

3

4

5

6

Step CHECK PRE-INSPECTION. 1) Ask the customer when and how the trouble occurred using the interview check list. 2) Before performing diagnostics, check the following items which might affect CVT problems. • General inspection • Disconnection of harness connector • Visual check for harness damage • Oil leakage • Stall speed test • Secondary pressure test • Transfer clutch pressure test • Time lag test • Road test • Inhibitor switch CHECK AT OIL TEMP LIGHT. Turn the ignition switch to ON and wait for at least 2 seconds. CHECK AT OIL TEMP LIGHT. Start the engine and wait for two seconds or more. CHECK INDICATION OF DTC. Read the DTC. NOTE: If the communication function of Subaru Select Monitor cannot be executed normally, check communication circuit. CHECK INFORMATION STORED IN FREEZE FRAME DATA. Using the Subaru Select Monitor, check the freeze frame data. PERFORM GENERAL DIAGNOSTICS. 1) Inspect using “Diagnostic Procedure without Diagnostic Trouble Code (DTC)”. 2) Inspect using “Diagnostics with Phenomenon”. 3) Perform the Inspection Mode. 4) Read the DTC.

Check Is the item that is thought to influence the CVT problem working properly?

Yes Go to step 2.

No Repair the items which may be affecting the CVT trouble.

Does the AT OIL TEMP light illuminate?

Go to step 3.

Check the AT OIL TEMP light.

Does the AT OIL TEMP light blink?

Go to step 4.

Go to step 6.

Is DTC displayed on Subaru Select Monitor?

Record all DTC. Go to step 5.

Go to step 6.

Are freeze frame data recorded?

Record the freeze Go to step 7. frame data. Go to step 7.

Is DTC displayed on Subaru Select Monitor?

Go to step 7.

CVT(diag)-2

Finish the diagnosis.

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Basic Diagnostic Procedure CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

7

Step Check PERFORM DIAGNOSIS. Is DTC displayed on Subaru 1) Inspect using “Diagnostic Procedure with Select Monitor? Diagnostic Trouble Code (DTC)”. NOTE: For DTC table, refer to “List of Diagnostic Trouble Code (DTC)”. 2) Repair the trouble cause. 3) Perform the Clear Memory Mode. 4) Perform the Inspection Mode. 5) Read the DTC.

CVT(diag)-3

Yes No Inspect using Finish the diagno“Diagnostic Proce- sis. dure with Diagnostic Trouble Code (DTC)”.

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Check List for Interview CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

2. Check List for Interview A: CHECK Check the following items when a problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer’s name Date of purchase Date of repair Transmission model Odometer reading Frequency Weather

Transmission

km (miles)

( Place ( Ambient air temperature Vehicle speed AT OIL TEMP light Select lever position Driving condition

Manual mode Symptoms

V.I.N.

Continuous Intermittent ( times/day) Fine Cloudy Rainy Snowy Others ) Highland Suburbs Inner city Uphill Others ) Hot Warm Cool Cold

Downhill

Rough road

km/h (MPH) Blinks continuously P R N Not affected At racing While decelerating

Does not blink Manual mode

D

At starting When accelerating While turning ( RH/ LH)

While idling While cruising (Vehicle speed km/h) Immediately after starting the engine

ON OFF Vehicle does not move ( Any position Particular position) Vehicle does not move (no load racing condition as in N range) Vehicle does not move (engine speed does not increase, felt as stall condition) Noise or vibration (Describe concretely: ) Shock felt at N → D selection ( seconds after shifting, when engine cold or after warm-up) Shock felt at N → R selection ( seconds after shifting, when engine cold or after warm-up) Shifting is wrong (Describe concretely: ) Shock or judder during driving Fails to accelerate. Engine speed increases abruptly during driving Shock or judder during standing start Select lever does not move Others ( )

CVT(diag)-4

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General Description CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

3. General Description A: CAUTION 1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG” The airbag system wiring harness is routed near the TCM. CAUTION: • All the airbag system wiring harnesses and connectors are colored yellow. Do not use an electric test equipment to check these circuits. • Be careful not to damage the airbag system wiring harness when performing diagnostics or servicing the TCM.

2. MEASUREMENT When measuring the voltage and resistance of the ECM, TCM or each sensor, use a tapered pin with a diameter of less than 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert a pin of more than 0.65 mm (0.026 in) diameter.

B: INSPECTION 1. BATTERY Measure the battery voltage and specific gravity of the electrolyte.

Standard voltage: 12 V or more Specific gravity: 1.260 or more

2. TRANSMISSION GROUND Make sure that the ground terminal bolt is tightened securely.

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

(APPROX. 45˚)

AT-05641

3. OPERATION OF SHIFT SELECT LEVER Make sure there is no noise, dragging or contact pattern in each select lever range. WARNING: Stop the engine while checking operation of the select lever.

CVT(diag)-5

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General Description CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 1B022XU0

DESCRIPTION SUBARU SELECT MONITOR III KIT

REMARKS Used for troubleshooting the electrical system.

ST1B022XU0

2. GENERAL TOOL TOOL NAME Circuit tester Oscilloscope

REMARKS Used for measuring resistance, voltage and current. Used for measuring the sensor.

CVT(diag)-6

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Electrical Component Location CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

4. Electrical Component Location A: LOCATION 1. CONTROL MODULE (1)

(3)

(4)

(5) (2),(6) AT-05571

(1)

Engine control module (ECM)

(3)

(2)

AT OIL TEMP light

(4)

Transmission control module (TCM) Data link connector

CVT(diag)-7

(5)

Body integrated unit

(6)

AWD light

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Electrical Component Location CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

(1)

AT OIL TEMP

(2) EN-07715

AT-05106

(4)

(3) (1) AT-05684

EN-07717

(5)

AWD

(6) AT-04405

CVT(diag)-8

AT-05395

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Electrical Component Location CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

2. SENSOR

(1)

(3)

(2)

(4) (5) AT-05398

(1) (2)

Secondary speed sensor Front wheel speed sensor

(3) (4)

Primary speed sensor Secondary pressure sensor

CVT(diag)-9

(5)

Inhibitor switch

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Electrical Component Location CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

3. SOLENOID UPR SIDE

(1) (2)

LWR SIDE

(5) (4) (3)

(6)

(7) AT-05397

(1) (2) (3)

Secondary solenoid AWD solenoid Lock-up duty solenoid

(4) (5)

Primary DOWN solenoid Primary UP solenoid

CVT(diag)-10

(6) (7)

F&R solenoid Lock-up ON/OFF solenoid

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Transmission Control Module (TCM) I/O Signal CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5. Transmission Control Module (TCM) I/O Signal A: ELECTRICAL SPECIFICATION

TO

B 54

TO

B 55

13 12 11 10 9 8 7 6 5 4 3 2 1

11 10 9 8 7 6 5 4 3 2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

22 21 20 19 18 17 16 15 14 13 12

AT-05105

NOTE: Measure after warming up. Resistance between terminal and chassis ground

Connector No.

Terminal No.

Measuring condition

Backup power supply

B55

1



10 — 13 V



Ignition power supply

B55

21



10 — 13 V



Main power supply Main power supply Main power supply

B55 B55 B55

11 2 22

— — —

10 — 13 V 10 — 13 V 10 — 13 V

— — —

Manual mode switch ON

Less than 1 V



Manual mode switch OFF

8 V or more



Paddle shift UP switch ON

Less than 1 V



Paddle shift UP switch OFF

8 V or more



Paddle shift DOWN switch ON

Less than 1 V



Paddle shift DOWN switch OFF

8 V or more



Stop light switch ON

8 V or more



Less than 1 V



Less than 1 V 8 V or more Less than 1 V 8 V or more

— — — —

Item

Manual mode switch

Manual mode UP switch

Manual mode DOWN switch

Stop light switch

B55

B55

B55

B55

4

5

16

13

P range switch

B54

5

R range switch

B54

18

Stop light switch OFF P range Except for P range R range Except for R range

Measured value

CVT(diag)-11

Remarks

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Transmission Control Module (TCM) I/O Signal CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS) Connector No.

Terminal No.

Measuring condition

N range switch

B54

9

N range Except for N range

Less than 1 V 8 V or more

Resistance between terminal and chassis ground — —

D range switch

B54

22

D range Except for D range

Less than 1 V 8 V or more

— —

ATF temperature at 20°C (68°F)

Approx. 2.6 V

Approx. 2.6 kΩ

ATF temperature at 80°C (176°F)

Approx. 0.7 V

Approx. 370 Ω

Item

Measured value

ATF temperature sensor

B54

ATF temperature sensor GND

B54

16

Always

Approx. 0 V



Secondary pressure sensor power supply output

B54

2

Ignition switch ON

5V



17

Ignition switch ON, engine OFF Ignition switch ON, engine ON

Approx. 0.5 V (0 MPa) Approx. 1.0 V (1.0 MPa)

3



Secondary pressure sensor

B54

Secondary pressure sensor GND

B54

15

Always

Approx. 0 V



Primary speed sensor

B54

6

While driving

0 or 5 V



Secondary speed sensor

B54

7

While driving

0 or 5 V



Front wheel speed sensor

B54

20

While driving

0 or 5 V



20

For three seconds after ignition ON Less than 1 V and OFF Ignition switch OFF 8 V or more

Self shut output

F&R solenoid

B55

B54

11

Engine ON

Refer to the waveform (solenoid (1))

Secondary solenoid

B54

12

Engine ON

Refer to the waveform (solenoid (2))

Primary UP solenoid

B54

24

Engine ON, while UP shifting

Refer to the waveform (solenoid (3))

Primary DOWN solenoid

B54

25

Engine ON, while DOWN shifting

Refer to the waveform (solenoid (4))

CVT(diag)-12



Remarks

Value increases with increase of engine load. (0.5 — 4.5 V)

Refer to the waveform (sensor) Refer to the waveform (sensor) Refer to the waveform (sensor)



Approx. 4 — 6 Ω

Resistance value at 20°C (68°F) Value is higher as the temperature increase.

Resistance value at 20°C (68°F) Approx. 5 — 7 Ω Value is higher as the temperature increase. Resistance value at 20°C (68°F) Approx. 10 — 13.5 Ω Value is higher as the temperature increase. Resistance value at 20°C (68°F) Approx. 10 — 13.5 Ω Value is higher as the temperature increase.

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Transmission Control Module (TCM) I/O Signal CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS) Connector No.

Item

Lock-up duty solenoid

AWD solenoid

B54

B54

Terminal No.

26

13

Measuring condition

Measured value

Lock-up ON

Refer to the waveform (solenoid (5))

Engine ON, “P” or “N” range

Refer to the waveform (solenoid (6))

Engine ON, “D” range, brake ON

Refer to the waveform (solenoid (7))

Lock-up OFF

Less than 1 V

Lock-up ON

Battery voltage or higher

Resistance between terminal and chassis ground

Resistance value at 20°C (68°F) Approx. 10 — 13.5 Ω Value is higher as the temperature increase. Resistance value at 20°C (68°F) Approx. 2 — 4.5 Ω Value is higher as the temperature increase. Resistance value at 20°C (68°F) Approx. 13 — 18.5 Ω Value is higher as the temperature increase.

Lock-up ON/OFF solenoid

B54

23

CAN communication line (+)

B55

18







CAN communication line (–)

B55

17







B54 B54

1 14

Approx. 0 V Approx. 0 V 8 V or more

— —

B55

19

GND GND Data link signal (Subaru Select Monitor)

Always Always Ignition switch ON

Ignition switch OFF Less than 1 V

B: WAVEFORM 1. SENSOR

0 FREQUENCY CHANGES ALONG WITH THE SPEED.

2V AT-04690

CVT(diag)-13

Remarks



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Transmission Control Module (TCM) I/O Signal CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

2. SOLENOID (1)

2ms

(2)

0V

50ms

0V

5V

5V AT-05529

(3)

AT-05531 (4)

1ms

1ms

0V

0V

10V

(5)

10V

AT-05532 (6)

1ms

0V

AT-05530

10ms

0V

10V

(7)

AT-05526

1ms

0V

10V

AT-05528

CVT(diag)-14

10V

AT-05527

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Subaru Select Monitor CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

6. Subaru Select Monitor A: OPERATION For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

CVT(diag)-15

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Read Current Data CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

7. Read Current Data A: OPERATION For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • The support data list is as follows. Item Engine speed signal Battery voltage Accelerator position sensor Vehicle speed converted from front vehicle speed sensor signal Lock-up duty solenoid set duty ratio AWD solenoid set duty ratio Turbine speed signal converted from primary speed sensor signal ATF temperature sensor signal Manual mode switch signal Manual mode down switch signal Stop light switch signal Manual mode up switch signal Drive range signal Reverse range signal AT OIL TEMP light 2 Hz blink condition AT OIL TEMP light ON condition Parking range signal Neutral range signal

Display Engine Speed Battery Voltage Accel. Opening Angle Front Wheel Speed Lock Up Duty Ratio Transfer Duty Ratio Turbine Revolution Speed ATF Temp. Manual Mode Switch Down Switch Stop Light Switch Up Switch D Range Signal R Range Signal Diagnosis Lamp ATF Temperature Lamp P Range N Range

AT learning mode condition

AT learning

Secondary speed sensor signal Secondary fluid pressure sensor signal Secondary solenoid set current Secondary solenoid actual current Gear ratio Shift step in manual mode Primary UP solenoid set duty ratio Primary DOWN solenoid set duty ratio

Secondary Pulley Speed Actual secondary pressure Sec. Sol. Set Current Sec. Sol. Actual Current Actual Gear Ratio Shift step in Manu. mode Primary UP Duty Primary DOWN Duty Commanded Forward & Reverse Linear Solenoid Current Actual Forward & Reverse Linear Solenoid Current Primary Pulley Speed Front Wheel Speed Lock-Up ON/OFF Solenoid

F&R solenoid set current F&R solenoid actual current Primary speed sensor signal Front vehicle speed sensor signal Lock-up ON/OFF solenoid set

CVT(diag)-16

Unit of measure rpm V % km/h or MPH % % rpm °C or °F ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF Completed or not completed rpm MPa mA mA — — % % mA mA rpm rpm ON or OFF

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Read Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

8. Read Diagnostic Trouble Code (DTC) A: OPERATION For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. NOTE: For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC).

CVT(diag)-17

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Clear Memory Mode CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

9. Clear Memory Mode A: OPERATION For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. CAUTION: • If {Clear Memories 2} is executed, learned control memory are cleared. • If {Clear Memories 2} is executed, perform learning.

CVT(diag)-18

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Inspection Mode CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

10.Inspection Mode A: PROCEDURE

CVT(diag)-19

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Learning Control CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

11.Learning Control

2. SIMPLE LEARNING

A: GENERAL DESCRIPTION

NOTE: Simple learning is performed with the vehicle lifted, without actually running the vehicle.

• Follow the messages displayed on the Subaru Select Monitor when working. • When the following work is performed, perform learning for the transmission. Replacement of TCM/Replacement or disassembly of transmission assembly/Replacement of control valve body/Performing “Clear Memories 2”.

B: PROCEDURE 1. PREPARATION FOR LEARNING 1) Warm up or cool down until the ATF temperature displayed on the Subaru Select Monitor is 40 — 65°C (104 — 149°F). 2) After stopping the vehicle, shift the select lever to “P” range. 3) Apply the electronic parking brake. 4) Lift up the vehicle. CAUTION: While working, be sure to keep the lower edge of the tires 30 cm or more above the ground as vehicle will vibrate. 5) Connect the Subaru Select Monitor to data link connector. 6) Turn the ignition switch to ON. 7) Turn off all switches causing an electrical load, such as headlights, A/C, seat heater and rear defogger.

CAUTION: Do not turn the power of the Subaru Select Monitor to OFF or disconnect the data link connector during the operation. 1) Select {AT related learning & inspecting mode} in the «Transmission Diagnosis» screen of the Subaru Select Monitor. 2) Select {AT learning mode} in the «AT related learning & inspecting mode» screen of the Subaru Select Monitor. 3) Follow the messages displayed on the Subaru Select Monitor screen when working. NOTE: During AT learning in progress, AT OIL TEMP light in the combination meter starts flashing at 2 Hz and the learning operation starts. The following message is displayed on the screen when the AT OIL TEMP light which was flashing at 2 Hz turns off.

CVT(diag)-20

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Learning Control CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

4) “AT learning normally ended.” is displayed, simple AT learning is completed. NOTE: • If communication error occurs during learning, retry the “AT learning mode” from the beginning. • If the message “Execute AT learning again after fixing troubles of the vehicle” is displayed during learning, select [OK] to display the List of Diagnostics Trouble Code. After repairing the locations indicated by the DTC, start the “AT learning mode” over from the beginning. • When communication error occurs during learning, select lever does not shift occasionally. If select lever does not shift, turn the ignition to OFF and operate the lever. • If the message “AT learning ended abnormally.” is displayed, start the “AT learning mode” over from the beginning. Message AT learning ended abnormally.

Primary cause of abnormal end • Fault is detected during AT learning. • The accelerator pedal is depressed during AT learning. • Operation which is not directed is performed during AT learning. • ATF temperature becomes out of specification during AT learning. • Battery voltage is low. • Malfunction indicator light illuminates. • Electronic parking brake not applied strongly enough • Brake pedal not stepped on firmly enough. • Abnormal idle speed increase, etc.

• For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

CVT(diag)-21

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AT OIL TEMP Warning Light Display CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

12.AT OIL TEMP Warning Light Display A: OPERATION The AT OIL TEMP light illuminates or blinks, when the ATF temperature is high and malfunction occurs in CVT. • When normal AT OIL TEMP light always illuminates when the ignition switch is ON (engine OFF). Light goes off after two seconds from engine ON. • When ATF temperature is high AT OIL TEMP light illuminates when the ATF temperature is abnormally high with engine ON. • When malfunction is detected AT OIL TEMP light blinks at 2 Hz when the TCM detects the malfunction of CVT with engine ON. In this case, inspect using “Diagnostic Procedure with Diagnostic Trouble Code (DTC)”. • When AT learning is not finished AT OIL TEMP light repeats “Blinking at 4 Hz → Turning OFF” every two seconds, when the AT learning is not finished with engine ON. In this case, perform the “Learning”. (During AT learning, the light blinks at 2 Hz or illuminates.) ON

(A)

OFF

ON

(B)

OFF

ON

(1)

OFF

ON

(2)

OFF

ON

(3)

OFF

ON

(4)

OFF

2 sec.

2 sec.

2 sec.

REPEATED

AT-05399

(A)

Ignition switch condition

(B)

Engine condition

(1) (2)

When normal When ATF temperature is high

(3)

When malfunction is detected

(4)

When AT learning is not finished

IF the AT OIL TEMP light does not illuminate, or illumination patterns are not as above, check the AT OIL TEMP light circuit.

CVT(diag)-22

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AT OIL TEMP Warning Light Display CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

B: INSPECTION DIAGNOSIS: • AT OIL TEMP light circuit is open or shorted. • Combination meter malfunction • TCM is in special control mode. • AT learning is not finished. TROUBLE SYMPTOM: • When the ignition switch is turned to ON, the AT OIL TEMP light does not illuminate. • AT OIL TEMP light remains lit after engine start. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT FB-30 F/B FUSE NO. 5 (IG) i10

19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

AT OIL TEMP

COMBINATION METER B55

32

33

i10

1 2 3 4 5 6 7 8 9 10 11

18

17

12 13 14 15 16 17 18 19 20 21 22

B 55

TCM

AT-05084

1

2

3

4

Step CHECK AT OIL TEMP LIGHT. Turn the ignition switch to ON.

Check Does the AT OIL TEMP light illuminate?

CHECK AT OIL TEMP LIGHT. Start the engine.

Yes Go to step 2.

No Perform self diagnosis of the combination meter. Go to step 3.

Does AT OIL TEMP light go off Current condition after two seconds from engine is normal. Go back start? to “Basic Diagnostic Procedure”.

CHECK DTC. Is DTC displayed? Perform the diag- Go to step 4. Read the DTC relating the TCM using the Subnosis according to aru Select Monitor. DTC. CHECK TCM. Is “ON” displayed? Go to step 5. Perform self diagRead the data of “ATF Temperature Lamp” nosis of the combiusing the Subaru Select Monitor. nation meter.

CVT(diag)-23

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AT OIL TEMP Warning Light Display CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

6

Step CHECK TCM. Read the data of ATF temperature using Subaru Select Monitor. CHECK ATF TEMPERATURE. Check the real fluid temperature from the transmission case surface temperature.

Check Is display 125 ºC or more?

Yes Go to step 6.

Does it clearly differ from the Perform the diag“ATF Temp.” displayed on Sub- nosis according to aru Select Monitor? DTC P0712 procedure. If there is no problems, perform the diagnosis according to DTC P0713 procedure.

CVT(diag)-24

No Check the TCM.

When ATF temperature can be judged as actually high, perform the diagnosis again after the ATF temperature lowers.

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AWD Warning Light Display CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

13.AWD Warning Light Display A: OPERATION AWD light illuminates or blinks, when the AWD is in special control condition and AWD has malfunction. • When normal AWD light always illuminates when the ignition switch is ON (engine OFF). Light goes off after two seconds from engine ON. • When FF mode is selected AWD light illuminates, when the AWD ON/OFF switching function is “FF mode” with engine ON. • When malfunction is detected AWD light blinks at 2 Hz when any of following malfunctions are detected with engine ON. 1. When tire with different diameter is installed, or air pressure of any of four wheels is excessively low 2. When “Rear differential inspection mode” is judged as NG

ON

(A)

OFF

ON

(B)

OFF

ON

(1)

OFF

ON

(2)

OFF

ON

(3)

OFF

2 sec.

AT-05462

(A)

Ignition switch condition

(B)

Engine condition

(1)

When normal

(2)

When FF mode is selected

(3)

When malfunction is detected

If the AWD light does not illuminate, or illumination patterns are not as above, check the AWD light circuit.

CVT(diag)-25

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AWD Warning Light Display CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

B: INSPECTION DIAGNOSIS: • AWD light circuit is open or shorted. • Combination meter malfunction • TCM is in AWD special control mode. TROUBLE SYMPTOM: • When the ignition switch is turned to ON, the AWD light does not illuminate. • AWD light remains lit after engine start. • AWD light is blinking immediately after engine start. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT

FB-30 F/B FUSE NO. 5 (IG) i10

19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 AWD WARNING LIGHT

COMBINATION METER B55

32

33

i10

1 2 3 4 5 6 7 8 9 10 11

18

17

12 13 14 15 16 17 18 19 20 21 22

B 55

TCM

AT-05463

1

2

3

4

5

Step CHECK AWD LIGHT. Turn the ignition switch to ON.

Check Yes Does the AWD light illuminate? Go to step 2.

CHECK AWD LIGHT. Start the engine.

No Perform self diagnosis of the combination meter. Go to step 3.

Does AWD light go off after two Current condition seconds from engine start? is normal. Go back to “Basic Diagnostic Procedure”.

CHECK DTC. Is DTC displayed? Perform the diag- Go to step 4. Read the DTC relating the TCM using the Subnosis according to aru Select Monitor. DTC. CHECK AWD LIGHT. Is AWD light illuminating? Go to step 6. Go to step 5. Check the display of AWD light after engine start. CHECK AWD LIGHT. Is AWD light blinking at 2 Hz? Go to step 7. Go to step 8. Check the display of AWD light after engine start.

CVT(diag)-26

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AWD Warning Light Display CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

6

7

8

Step CHECK AWD ON/OFF SWITCHING FUNCTION. Using the Subaru Select Monitor, select the {AWD ON/OFF switching mode} from «AT related learning & inspecting mode», and check the current mode. CHECK REAR DIFFERENTIAL. Using the Subaru Select Monitor, select the {Rear differential inspection mode} from «AT related learning & inspecting mode», and check.

CHECK COMBINATION METER. Perform self diagnosis of the combination meter.

Check Yes Is the message “Currently, vehi- Go to step 8. cle is AWD. Do you change to FF?” displayed?

No If the message “At present, the vehicle is in FF. Switch to AWD?” is displayed, select “OK”, and switch to AWD mode. Go to step 8.

Does AWD light go off after Current condition inspection is finished normally? is normal. Go back to “Basic Diagnostic Procedure”.

Is there any trouble with the Repair the combi- Check the TCM. combination meter? nation meter.

CVT(diag)-27

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Diagnostic Procedure for Subaru Select Monitor Communication CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

14.Diagnostic Procedure for Subaru Select Monitor Communication A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE DIAGNOSIS: Defective harness connector TROUBLE SYMPTOM: Subaru Select Monitor communication failure WIRING DIAGRAM: B11 BATTERY 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

E

SBF-5

M/B No. 1

MAIN SBF

5

B40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

M/B No. 12

16 7

IGNITION SWITCH

5 4

A : B 134

DATA LINK CONNECTOR

B40

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

C4

C: B136

F/B No. 12

A : B134 ECM

36

B19

B21

B22

B2

B11

B1

A:

B 21 E2

13

B54

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

TCM

B55

B: B55

E

A14

B:

20

B54

A1

A:

5 6 14 15 16 25 26 27 33 34 35

A6

C : B136

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

B 11

B21

T4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 42

E

36

35 43 48

49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

AT-05554

1

Step CHECK INSTALLATION OF TCM CONNECTOR. Turn the ignition switch to OFF.

Check Yes Is TCM connector connected to Go to step 2. TCM?

CVT(diag)-28

No Connect the TCM connector to TCM.

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Diagnostic Procedure for Subaru Select Monitor Communication CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

2

3

4

5 6

7

8

Step Check CHECK SUBARU SELECT MONITOR POW- Is the voltage 10 V or more? ER SUPPLY CIRCUIT.. Measure the voltage between data link connector and chassis ground. Connector & terminal (B40) No. 16 (+) — Chassis ground (–): CHECK SUBARU SELECT MONITOR GROUND CIRCUIT. 1) Disconnect the ECM connector. 2) Measure the resistance of harness between data link connector and ECM. Connector & terminal (B40) No. 4 — (B136) No. 4: (B40) No. 5 — (B136) No. 4: CHECK SUBARU SELECT MONITOR GROUND CIRCUIT. Measure the resistance of harness between data link connector and chassis ground. Connector & terminal (B40) No. 16 — Chassis ground: CHECK ENGINE GROUND CIRCUIT. Check the engine ground circuit. CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to ON. 2) Check the communication with the transmission. CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM connector. 3) Turn the ignition switch to ON. 4) Check communication with the engine system. CHECK OUTPUT SIGNAL OF TCM. 1) Turn the ignition switch to OFF. 2) Connect the connector to the TCM. 3) Disconnect the control modules connectors which connecting to the data link connector (B40) No. 7, other than the TCM and ECM. CAUTION: When disconnecting the connector from airbag control module, always follow the precautions on AB section. 4) Turn the ignition switch to ON. 5) Check communication with the transmission system.

Yes Go to step 3.

Is the resistance less than 1 Ω? Go to step 4.

Is the resistance 1 MΩ or more?

Go to step 5.

No Repair harness connector between the battery and data link connector, and poor contact of the connector. Repair the open circuit of harness between data link connector and ECM.

Repair the short circuit of harness between data link connector and ground terminals.

Is the engine ground circuit nor- Go to step 6. mal? Is the name of system disGo to step 11. played on Subaru Select Monitor?

Repair ground circuit of ECM. Go to step 7.

Is the name of system disGo to step 9. played on Subaru Select Monitor?

Go to step 8.

Is the name of system disCheck each control Go to step 9. played on Subaru Select Moni- module. tor?

CVT(diag)-29

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Diagnostic Procedure for Subaru Select Monitor Communication CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS) Step CHECK HARNESS CONNECTOR BETWEEN EACH CONTROL MODULE AND DATA LINK CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors of all control modules connected to the data link connector (B40) No. 7. 3) Measure the resistance between data link connector and chassis ground. Connector & terminal (B40) No. 7 — Chassis ground: CHECK OUTPUT SIGNAL OF TCM. 1) Turn the ignition switch to ON. 2) Measure the voltage between data link connector and chassis ground. Connector & terminal (B40) No. 7 (+) — Chassis ground (–): CHECK HARNESS CONNECTOR BETWEEN TCM AND DATA LINK CONNECTOR. 1) Disconnect the TCM connector. 2) Measure the resistance between TCM connector and data link connector. Connector & terminal (B40) No. 7 — (B55) No. 19: CHECK INSTALLATION OF TRANSMISSION HARNESS CONNECTOR.

Check Is the resistance 1 MΩ or more?

13

CHECK POOR CONTACT OF CONNECTORS.

14

Is there poor contact of control Repair the poor module power supply and data contact. link connector? Is the voltage 10 — 13 V? Go to step 16.

CHECK TCM POWER SUPPLY. 1) Disconnect the TCM connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 1 (+) — Chassis ground (–): (B55) No. 2 (+) — Chassis ground (–): (B55) No. 11 (+) — Chassis ground (–): (B55) No. 22 (+) — Chassis ground (–): CHECK M/B FUSE (NO. 1). Is the fuse (No. 1) blown out? 1) Turn the ignition switch to OFF. 2) Remove the fuse (No. 1).

9

10

11

12

15

16

CHECK IGNITION POWER SUPPLY CIRCUIT. 1) Turn the ignition switch to ON. 2) Measure the ignition power supply voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 21 (+) — Chassis ground (–):

Yes Go to step 10.

No Check harness and connector between each control module and data link connector.

Is the voltage 1 V or more?

Check harness Go to step 11. and connector between each control module and data link connector. Is the resistance less than 1 Ω? Go to step 12. Check the harness and connector between TCM and data link connector.

Is the transmission harness connector connected to bulkhead harness connector?

Is the voltage 10 — 13 V?

CVT(diag)-30

Go to step 13.

Replace the fuse. If the replaced fuse blows out easily, repair the short circuit in the harness between the fuse and the TCM. Go to step 18.

Connect the bulkhead harness connector to transmission harness connector. Go to step 14.

Go to step 15.

Repair the open circuit of harness between the fuse and the TCM, or the fuse and battery, and poor contacts of connectors. Go to step 17.

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Diagnostic Procedure for Subaru Select Monitor Communication CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

17

18

19

20

Step CHECK F/B FUSE (NO. 12). Remove the fuse (No. 12).

Check Yes Is the fuse (No. 12) blown out? Replace the fuse. If the replaced fuse blows out easily, repair the short circuit in the harness between the fuse and the TCM.

CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 1 — (B11) No. 13: (B54) No. 14 — (B11) No. 20: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND TRANSMISSION GROUND. Measure the resistance of the harness between transmission and transmission ground. Connector & terminal (T4) No. 13 — Transmission ground: (T4) No. 20 — Transmission ground: CHECK POOR CONTACT OF CONNECTORS.

Is the resistance less than 1 Ω? Go to step 19.

Is the resistance less than 1 Ω? Go to step 20.

No Repair the open circuit of harness between the fuse and the TCM, or the fuse and battery, and poor contacts of connectors. Repair the open circuit of harness between TCM and transmission harness connector, and poor contact of connector.

Repair the open circuit of the harness between transmission and transmission ground.

Is there poor contact of TCM Repair the connec- Check the TCM. power supply, ground and data tor. link connector?

CVT(diag)-31

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List of Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

15.List of Diagnostic Trouble Code (DTC) A: LIST DTC

Item

Content of diagnosis

Reference

P0705

Transmission Range Sensor Circuit (PRNDL Input)

Inhibitor switch malfunction or short circuit

P0708

AT Range Switch Not Inputted

Inhibitor switch malfunction or open circuit

P0712

Transmission Fluid Temperature Sensor Circuit Low Input

ATF temperature sensor is faulty or input signal circuit is shorted.

P0713

Transmission Fluid Temperature Sensor Circuit High Input

ATF temperature sensor is faulty or input signal circuit is open or shorted.

P0719

Brake Switch Circuit Low

Brake switch malfunction, open or shorted input signal circuit

P0720

Output Speed Sensor Circuit

Front wheel speed sensor is faulty or input signal circuit is open or shorted.

P0724

Brake Switch Circuit High

Brake switch malfunction, shorted input signal circuit

P0730

Gearshift Control Performance Abnormal

Primary speed sensor, secondary speed sensor, control valve, or chain malfunction

P0801

Reverse Inhibit Control Circuit

P0841

Secondary Oil Pressure Sensor Performance

P0842

Secondary Oil Pressure Sensor Circuit (Low)

Secondary pressure sensor is faulty or input signal circuit is open or shorted.

P0843

Secondary Oil Pressure Sensor Circuit (High)

Secondary pressure sensor is faulty or input signal circuit is shorted.

P0890

AT Self-Shut Relay Diag- Self-shut relay malfunction, open or shorted input signal circuit nosis (Low)

P0951

Manual Switch

Manual mode switch malfunction, open or shorted input signal circuit

P0962

Secondary Solenoid Circuit (Low)

Secondary solenoid is faulty or output signal circuit is shorted.



Shift lock solenoid is faulty or out-

CVT(diag)-32



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List of Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS) DTC

Item

Content of diagnosis

P0963

Secondary Solenoid Circuit (High)

P0965

Forward & Reverse Sole- F&R solenoid, forward clutch or noid Function control valve malfunction

P0966

Forward & Reverse Sole- F&R solenoid is faulty or output noid Circuit (Low) signal circuit is shorted.

P0967

Forward & Reverse Linear Solenoid Circuit (High)

F&R solenoid is faulty or output signal circuit is open or shorted.

P0970

Transfer Solenoid Circuit (Low)

AWD solenoid is faulty or output signal circuit is shorted.

P0971

Transfer Solenoid Circuit (High)

AWD solenoid is faulty or output signal circuit is open or shorted.

P0973

Primary Solenoid System A Circuit (Low)

Primary UP solenoid is faulty or output signal circuit is shorted.

P0974

Primary Solenoid System A Circuit (High)

Primary UP solenoid is faulty or output signal circuit is open or shorted.

P0976

Primary Solenoid System B Circuit (Low)

Primary DOWN solenoid is faulty or output signal circuit is shorted.

P0977

Primary Solenoid System B Circuit (High)

Primary DOWN solenoid is faulty or output signal circuit is open or shorted.

P1718

AT CAN Communication Circuit

• CAN communication is open or shorted. • ECM, ABS/VDCCM CAN communication error

P1724

AT EEPROM Error

TCM EEPROM malfunction

P1725

AT Body System CAN Communication Trouble

Combination meter, A/C, body integrated unit CAN communication error

P2746

Primary Pulley Revolution Speed Sensor Circuit

Primary speed sensor malfunction, open or shorted input signal circuit

Secondary solenoid is faulty or output signal circuit is open or shorted.

CVT(diag)-33

Reference







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List of Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS) DTC

Item

Content of diagnosis

Reference

P2750

Sec. Pulley Revolution Speed Sensor Circuit

Secondary speed sensor malfunction, open or shorted input signal circuit

P2762

Lock-Up Duty Solenoid Malfunction

Lock-up duty solenoid, lock-up clutch or control valve malfunction

P2763

Lock-Up Duty Solenoid Circuit (High)

Lock-up duty solenoid is faulty or output signal circuit is open or shorted.

P2764

Lock-Up Duty Solenoid Circuit (Low)

Lock-up duty solenoid is faulty or output signal circuit is shorted.

P2769

Lock-Up ON/OFF Solenoid Circuit (Low)

Lock-up ON/OFF solenoid is faulty or output signal circuit is shorted.

P2770

Lock-Up ON/OFF Solenoid Circuit (High)

Lock-up ON/OFF solenoid is faulty or output signal circuit is open or shorted.

CVT(diag)-34



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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

16.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT) DTC DETECTING CONDITION: • Inhibitor switch is faulty. • At least 2 range signal is input. TROUBLE SYMPTOM: • Shift characteristics are erroneous. • The range position of the select lever and the position of shift indicator display do not match. WIRING DIAGRAM: B54

TCM

9

22

5

18

B12 1 2 3 4 5 6 7 8 9 10 11 12

8

1

2

3

B12 T3 4

3

5

2

T7

P

1 2 3 4 5 6 7 8 9

INHIBITOR SWITCH

R N

T7 1

D

B54

4

T3

1 2 3 4 5 6 7 8 9 10 11 12 13

B 12

14 15 16 17 18 19 20 21 22 23 24 25 26

E AT-05086

1

2

3

Step CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to ON. 2) Move the select lever to each range, read the data of “P, R, N, D range” using the Subaru Select Monitor. CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 5 — Chassis ground: (B54) No. 18 — Chassis ground: (B54) No. 9 — Chassis ground: (B54) No. 22 — Chassis ground: CHECK HARNESS. 1) Disconnect the inhibitor switch connector. 2) Measure the resistance between transmission connector and inhibitor switch connector. Connector & terminal (T3) No. 3 — (T7) No. 2: (T3) No. 2 — (T7) No. 5: (T3) No. 1 — (T7) No. 3: (T3) No. 8 — (T7) No. 4:

Check Is display “OFF” for the range other than corresponding range?

Yes Go to step 5.

No Go to step 2.

Is each resistance 1 MΩ or more?

Go to step 3.

Repair the short circuit of harness.

Is each resistance 1 MΩ or more?

Go to step 4.

Repair the short circuit of harness.

CVT(diag)-35

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

4

5

Step CHECK INHIBITOR SWITCH. Move the select lever to each range, and measure the resistance between inhibitor switch connector terminals Connector & terminal (T7) No. 2 — (T7) No. 1: (T7) No. 5 — (T7) No. 1: (T7) No. 3 — (T7) No. 1: (T7) No. 4 — (T7) No. 1: CHECK FOR POOR CONTACT.

Check Yes Is the resistance other than cor- Go to step 5. responding range 1 MΩ or more?

No Replace the inhibitor switch.

Is there poor contact between Repair the poor TCM, inhibitor switch, transmis- contact. sion ground?

Check the TCM.

CVT(diag)-36

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

B: DTC P0708 AT RANGE SWITCH NOT INPUTTED DTC DETECTING CONDITION: • Inhibitor switch is faulty. • No range signal is input. TROUBLE SYMPTOM: • Shift characteristics are erroneous. • The range position of the select lever and the position of shift indicator display do not match. WIRING DIAGRAM: B54

TCM

9

1 2 3 4 5 6 7 8 9 10 11 12

22

5

18

B12

8

1

2

3

B12 T3 4

3

5

2

T7

P

1 2 3 4 5 6 7 8 9

INHIBITOR SWITCH

R N

T7 1

D

B54

4

T3

1 2 3 4 5 6 7 8 9 10 11 12 13

B 12

14 15 16 17 18 19 20 21 22 23 24 25 26

E AT-05086

1

2

3

Step CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to ON. 2) Move the select lever to each range, read the data of “P, R, N, D range” using the Subaru Select Monitor. CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 5 — (B12) No. 3: (B54) No. 18 — (B12) No. 2: (B54) No. 9 — (B12) No. 1: (B54) No. 22 — (B12) No. 8: CHECK HARNESS. Measure the resistance of harness between transmission connector and transmission ground. Connector & terminal (B12) No. 4 — Transmission ground:

Check Is the display of the corresponding range “ON”?

Yes Go to step 7.

No Go to step 2.

Is each resistance less than 1 Ω?

Go to step 3.

Repair the open circuit of harness.

Is the resistance less than 1 Ω? Go to step 4.

Repair the open circuit of harness.

CVT(diag)-37

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

4

5

6

7

Step CHECK HARNESS. 1) Disconnect the inhibitor switch connector. 2) Measure the resistance between transmission connector and inhibitor switch connector. Connector & terminal (T3) No. 3 — (T7) No. 2: (T3) No. 2 — (T7) No. 5: (T3) No. 1 — (T7) No. 3: (T3) No. 8 — (T7) No. 4: (T3) No. 4 — (T7) No. 1: CHECK INHIBITOR SWITCH. Move the select lever to each range, and measure the resistance between inhibitor switch connector terminals Connector & terminal (T7) No. 2 — (T7) No. 1: (T7) No. 5 — (T7) No. 1: (T7) No. 3 — (T7) No. 1: (T7) No. 4 — (T7) No. 1: CHECK HARNESS. 1) Turn the ignition switch to ON. 2) Measure the voltage between each connector and chassis ground. Connector & terminal Transmission connector (B12 side) (B12) No. 3 (+) — Chassis ground (–): (B12) No. 2 (+) — Chassis ground (–): (B12) No. 1 (+) — Chassis ground (–): (B12) No. 8 (+) — Chassis ground (–): (B12) No. 4 (+) — Chassis ground (–): Transmission connector (T7 side) (T7) No. 2 (+) — Chassis ground (–): (T7) No. 5 (+) — Chassis ground (–): (T7) No. 3 (+) — Chassis ground (–): (T7) No. 4 (+) — Chassis ground (–): (T7) No. 1 (+) — Chassis ground (–): CHECK FOR POOR CONTACT.

Check Is each resistance less than 1 Ω?

Yes Go to step 5.

No Repair the open circuit of harness.

Is the resistance of the corresponding range less than 1 MΩ?

Go to step 6.

Replace the inhibitor switch.

Is each voltage less than 1 V?

Go to step 7.

Repair the harness which outputs 1 V or more.

Is there poor contact between Repair the poor TCM, inhibitor switch, transmis- contact. sion ground?

CVT(diag)-38

Check the TCM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

C: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW INPUT DTC DETECTING CONDITION: Input signal circuit of ATF temperature sensor is shorted. TROUBLE SYMPTOM: • Excessive shift shock • Shift characteristics malfunction WIRING DIAGRAM: B54

TCM

3 16

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

16 19

B11 T4

ATF TEMPERATURE SENSOR

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

AT-05087

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 3 — Chassis ground: (B54) No. 16 — Chassis ground: CHECK HARNESS. Measure the resistance between TCM connector and transmission body. Connector & terminal (T4) No. 16 — Transmission body: (T4) No. 19 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage. CHECK ATF TEMPERATURE SENSOR. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 16 — No. 19:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit of harness.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the short circuit of harness.

Is there any malfunction in har- Go to step 4. ness?

Replace the transmission harness.

Is resistance as follows? Fluid temperature 0ºC → approx. 6.2 kΩ Fluid temperature 20ºC → approx. 2.6 kΩ Fluid temperature 80ºC → approx. 370 Ω

Replace the transmission harness.

CVT(diag)-39

Check the TCM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

D: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Input signal circuit of ATF temperature sensor is open or shorted. TROUBLE SYMPTOM: • Excessive shift shock • Shift characteristics malfunction WIRING DIAGRAM: B54

TCM

3 16

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

16 19

B11 T4

ATF TEMPERATURE SENSOR

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

AT-05087

Step CHECK HARNESS. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM connectors. Connector & terminal (B54) No. 3 (+) — (B54) No. 16 (–): CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 3 — (B11) No. 16: (B54) No. 16 — (B11) No. 19: CHECK ATF TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Connect the connectors to TCM and transmission. 3) Start the engine. 4) Warm up until the ATF temperature exceeds 50°C (122°F). 5) Turn the ignition switch to OFF. 6) Disconnect the transmission connector. 7) Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 16 — No. 19:

Check Is the voltage 5 V or more?

Yes Repair the short circuit of harness.

Is the resistance less than 1 Ω? Go to step 3.

Is the resistance 730 — 1120 Ω?

CVT(diag)-40

Go to step 4.

No Go to step 2.

Repair the open circuit of harness.

Go to step 6.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

4

5

6

Step CHECK ATF TEMPERATURE SENSOR. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 16 — No. 19: CHECK INPUT SIGNAL FOR TCM. 1) Connect the connector to transmission. 2) Turn the ignition switch to ON. (Do not start engine.) 3) Read the data of ATF temperature using Subaru Select Monitor.

Check Does the resistance value increase gradually while the ATF temperature decreases?

Yes Go to step 5.

Does the ATF temperature gradually decrease?

CHECK FOR POOR CONTACT.

Is there poor contact of ATF temperature sensor circuit?

Check for poor Go to step 6. contact of the ATF temperature sensor and transmission connector harness, and repair the fault location. Repair the poor Check the TCM. contact.

CVT(diag)-41

No Replace the transmission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

E: DTC P0719 BRAKE SWITCH CIRCUIT LOW DTC DETECTING CONDITION: Brake switch malfunction or input signal circuit of brake switch is open or shorted. TROUBLE SYMPTOM: • Gear is not shifted down when climbing a hill or driving down a hill. • Neutral control does not operate. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT

B65

FB-2 F/B FUSE NO. 8 (B)

1 3

*1

*1

2 4

3

2

B 512

B 65

B512

*2

J/C

STOP LIGHT & BRAKE SWITCH

J/C

1 2 3 4 5 6 7 8

*2

B 512

B55

*2

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 5 AND 6

13

*1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 3, 4, 7 AND 8

B55

TCM

AT-05555

1

2

3

4

Step CHECK FUSE (NO. 8). 1) Turn the ignition switch to OFF. 2) Remove the fuse (No. 8).

Check Is the fuse (No. 8) blown out?

Yes No Replace the fuse Go to step 2. (No. 8). If the new fuse (No. 8) has blown out easily, repair the short circuit of harness between fuse (No. 8) and stop light switch. Is the resistance less than 1 Ω? Go to step 3. Repair the open circuit of harness.

CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and stop light switch connector. 3) Measure the resistance between TCM connector and stop light switch connector. Connector & terminal (B55) No. 13 — (B65) No. 3: CHECK HARNESS. Is the resistance less than 1 Ω? Go to step 4. Measure the resistance between TCM connector and fuse (No. 8). Connector & terminal (B65) No. 2 — fuse (No. 8): CHECK INPUT SIGNAL FOR TCM. Is the voltage 10 V or more? Go to step 5. 1) Install the fuse (No. 8). 2) Connect the TCM and stop light switch connector. 3) Depress the brake pedal. 4) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 13 (+) — Chassis ground (–):

CVT(diag)-42

Repair the open circuit of harness.

Replace the stop light switch.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

6

Step CHECK INPUT SIGNAL FOR TCM. With brake pedal depressed, read the data of “Stop lamp SW” using Subaru Select Monitor.

Check Is “ON” displayed?

CHECK FOR POOR CONTACT.

Is there poor contact of input signal of stop light switch?

CVT(diag)-43

Yes No Current condition Go to step 6. is normal. Check for poor contact of the connector or harness, and repair the fault location. Repair the poor Check the TCM. contact.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT DTC DETECTING CONDITION: • Input signal circuit of TCM is open or shorted. • Front wheel speed sensor malfunction TROUBLE SYMPTOM: • Excessive shift shock on N → D or N → R. • Driving performance is poor. • Neutral control does not operate. WIRING DIAGRAM: AT5

B54

TCM

20 1

1 2 3 TO POWER SUPPLY CIRCUIT

No. 38 7.5A

1

B11

2 B11 M/B

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

7 12 13

MB-44 M/B FUSE NO. 1 (IG)

5

T4

1 2 3

B54 1 2 3 4 5 6 7 8 9 10 11 12 13

AT5

14 15 16 17 18 19 20 21 22 23 24 25 26

FRONT WHEEL SPEED SENSOR

AT-05089

1

2

3

Step CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse (No. 38).

Check Is the fuse OK?

Yes Go to step 2.

CHECK HARNESS. Is the resistance less than 1 Ω? Go to step 3. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 1 — (B11) No. 13: (B54) No. 20 — (B11) No. 12: (M/B No. 38) No. 2 — (B11) No. 7: CHECK HARNESS. Is the resistance 1 MΩ or Go to step 4. Measure the resistance between TCM connec- more? tor and chassis ground. Connector & terminal (B11) No. 7 — Chassis ground: (B11) No. 12 — Chassis ground:

CVT(diag)-44

No Replace the fuse. If the fuse blows out easily, repair the short circuit of harness. Repair the open circuit of harness.

Repair the short circuit of harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

4

5

6

Step CHECK TRANSMISSION HARNESS. 1) Connect the TCM connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B11) No. 12 (+) — Chassis ground (–): NOTE: Delete the TCM memory after completing the CVT control system diagnosis. CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to OFF. 2) Connect the transmission connector. 3) Lift up the vehicle. 4) Start the engine. 5) Slowly increase the speed to 30 km/h (18 MPH). 6) Read the data of “Front Wheel Speed” using Subaru Select Monitor. CHECK TRANSMISSION HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the transmission connector. 3) Lift up the vehicle. 4) Disconnect the front wheel speed sensor connector. 5) Measure the resistance between transmission connector and front wheel speed sensor connector. Connector & terminal (T4) No. 7 — (AT5) No. 1: (T4) No. 12 — (AT5) No. 2: (T4) No. 13 — (AT5) No. 3:

Check Is the voltage approx. 5 V?

Yes Go to step 5.

No Repair the open circuit of harness or poor contact of connector.

Does the value of “Front Wheel Current condition Go to step 6. Speed” change according to is normal. Repair the engine speed? the poor contacts of harnesses of front wheel speed sensor and transmission connector.

Is the resistance less than 1 Ω? Replace the front Replace the transwheel speed sen- mission harness. sor.

CVT(diag)-45

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

G: DTC P0724 BRAKE SWITCH CIRCUIT HIGH DTC DETECTING CONDITION: Brake switch malfunction or input signal circuit of brake switch is shorted. TROUBLE SYMPTOM: • Gear is not shifted down when driving a down hill. • Neutral control does not operate. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT

B65

FB-2 F/B FUSE NO. 8 (B)

1 3

*1

*1

2 4

3

2

B 512

B 65

B512

*2

J/C

STOP LIGHT & BRAKE SWITCH

J/C

1 2 3 4 5 6 7 8

*2

B 512

B55

*2

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 5 AND 6

13

*1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 3, 4, 7 AND 8

B55

TCM

AT-05555

1

2

3

4

Step CHECK STOP LIGHT SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the stop light switch connector. 3) Measure the resistance of harness between stop light switch connectors. Connector & terminal (B65) No. 2 — No. 3: CHECK HARNESS. 1) Disconnect the TCM connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 13 (+) — Chassis ground (–): CHECK INPUT SIGNAL FOR TCM. 1) Connect the TCM and stop light switch connector. 2) Turn the ignition switch to ON. 3) Read the data of “Stop Light Switch” using Subaru Select Monitor.

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Replace the stop light switch.

Is the voltage 10 V or more?

Repair the short circuit of harness.

Go to step 3.

Is “OFF” displayed?

CHECK FOR POOR CONTACT.

Is there poor contact of input signal of stop light switch?

Current condition Go to step 4. is normal. Check for poor contact of the connector or harness, and repair the fault location. Repair the poor Check the TCM. contact.

CVT(diag)-46

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

H: DTC P0730 GEARSHIFT CONTROL PERFORMANCE ABNORMAL DTC DETECTING CONDITION: • Control valve hydraulic circuit malfunction • Primary UP solenoid, primary Down solenoid characteristics malfunction • CVT chain slippage TROUBLE SYMPTOM: • Acceleration is poor during standing start. • Shift control malfunction • Engine speed increases abruptly. Step CHECK TRANSMISSION FLUID. Check the condition of ATF.

Check Is the ATF OK?

Yes Go to step 2.

2

CHECK TRANSMISSION FLUID. Check the amount of ATF.

Is the ATF amount correct?

Go to step 3.

3

CHECK INPUT SIGNAL FOR TCM. 1) Lift up the vehicle. 2) Start the engine. 3) Warm up until the ATF temperature reaches to 40 — 70°C (104 — 158°F). 4) Shift the select lever to “P” range. 5) Stabilize the engine speed at idle. 6) Read the data of “Actual secondary pressure” using Subaru Select Monitor. CHECK INPUT SIGNAL FOR TCM. Read the data of “Actual Gear Ratio” using Subaru Select Monitor. CHECK INPUT SIGNAL FOR TCM. 1) Set the select lever to the “D” range. 2) Slowly increase the speed to 40 km/h (24 MPH) and keep the constant speed. 3) Read the data of “Actual Gear Ratio” using Subaru Select Monitor. DRIVING CHECK BY INSPECTION MODE. 1) Turn the ignition switch to OFF. 2) Perform a drive check based on the “Inspection Mode”.

Is “Actual secondary pressure” Go to step 4. 0.5 — 1.5 MPa?

1

4

5

6

Is “Actual Gear Ratio” 2.0 — 2.4?

Go to step 5.

Is “Actual Gear Ratio” 0.5 — 0.8?

Go to step 6.

Does the AT OIL TEMP light blink and is DTC P0730 displayed?

CVT(diag)-47

No Check according to the “corrective action” of ATF (CVTF) “CONDITION CHECK”.

Adjust the amount of ATF. Perform the diagnosis according to DTC P0841 procedure.

Go to step 6.

Replace the transmission assembly.

Replace the trans- If there is shift mission assembly. problems, abrupt

replace the transmission assembly. If it is normal, temporary poor contact occurs.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

I:

DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT

NOTE: DTC P0801 AT shift lock solenoid circuit, refer to “LAN System”.

CVT(diag)-48

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

J: DTC P0841 SECONDARY OIL PRESSURE SENSOR PERFORMANCE DTC DETECTING CONDITION: • Control valve hydraulic circuit malfunction • Secondary pressure sensor fault or characteristics malfunction TROUBLE SYMPTOM: • Acceleration is poor during standing start. • Shift control malfunction • Engine speed increases abruptly. WIRING DIAGRAM: TCM

AT6

B54

2 17 15

1 2 3

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

17 14 18

B11 T4

1 2 3

B54 1 2 3 4 5 6 7 8 9 10 11 12 13

AT6

14 15 16 17 18 19 20 21 22 23 24 25 26

SECONDARY PRESSURE SENSOR

1

2

AT-05090

Step CHECK DTC. Read the DTC using Subaru Select Monitor.

CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to ON. 2) Read the data of «Actual secondary pressure» using Subaru Select Monitor. (While shaking the secondary pressure sensor harness)

Check Are DTCs other than P0841 displayed?

Yes No Perform the diag- Go to step 2. nosis according to DTC. After the diagnosis, start the engine, and drive for 20 minutes in any driving pattern. (Include driving at a constant legal speed (for 20 seconds) at least once.) Read the DTC, and if P0841 alone is detected, Go to step 2. Is the «Actual secondary pres- Go to step 10. Go to step 3. sure» 0 — 0.17 MPa?

CVT(diag)-49

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

3

4

5

6

7

8

9

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the connector of TCM and secondary pressure sensor. 3) Measure the resistance between TCM connector and secondary pressure sensor connector. Connector & terminal (B54) No. 2 — (AT6) No. 1: (B54) No. 15 — (AT6) No. 3: (B54) No. 17 — (AT6) No. 2: CHECK HARNESS. Measure the resistance between TCM connectors. Connector & terminal (B54) No. 2 — (B54) No. 17: (B54) No. 15 — (B54) No. 2: (B54) No. 17 — (B54) No. 15: CHECK HARNESS. Measure the resistance between TCM connector and transmission body. Connector & terminal (B54) No. 2 — Transmission body: (B54) No. 15 — Transmission body: (B54) No. 17 — Transmission body: CHECK POWER SUPPLY FOR SECONDARY PRESSURE SENSOR. 1) Connect the TCM connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between TCM connectors. Connector & terminal (B54) No. 2 (+) — (B54) No. 15 (–): CHECK POWER SUPPLY FOR SECONDARY PRESSURE SENSOR. 1) Turn the ignition switch to OFF. 2) Connect the secondary pressure sensor connector. 3) Turn the ignition switch to ON. 4) Measure the voltage between TCM connectors. Connector & terminal (B54) No. 2 (+) — (B54) No. 15 (–): CHECK SECONDARY PRESSURE SENSOR OUTPUT. Measure the voltage between TCM connectors. Connector & terminal (B54) No. 17 (+) — (B54) No. 15 (–):

Yes Check Is the resistance less than 1 Ω? Go to step 4.

No Repair the open circuit of harness.

Is the resistance 1 MΩ or more?

Go to step 5.

Repair the short circuit of harness.

Is the resistance 1 MΩ or more?

Go to step 6.

Repair the short circuit of harness.

Is the voltage 4.6 — 5.4 V?

Go to step 7.

Is the voltage 4.6 — 5.4 V?

Go to step 8.

Check for poor contact of connector, and if no fault is found, replace the TCM. Replace the secondary pressure sensor.

Is the voltage 0.39 — 0.61 V?

Check for poor Go to step 9. contact of connector, and if no fault is found, replace the TCM. Repair the connec- Go to step 10. tor, or replace harness.

CHECK CONNECTOR. Is there any fault in the TCM 1) Turn the ignition switch to OFF. connector or the secondary 2) Disconnect the connector of TCM and sec- pressure connector? ondary pressure sensor. 3) Check the TCM connector (B54) and the secondary pressure sensor connector (AT6).

CVT(diag)-50

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

10

11

12

13

14

Step Check CHECK TRANSMISSION FLUID. Is the ATF amount correct? 1) Connect all connectors. 2) Check the amount of ATF. CHECK INPUT SIGNAL FOR TCM. 1) Perform the Clear Memory Mode. 2) Start the engine. 3) Warm up until the ATF temperature reaches to 40 — 70°C (104 — 158°F). 4) Depress the brake pedal and move the select lever to each range at an interval of five seconds. NOTE: Move the select lever in the following order: “P” → “R” → “N” → “D” → “N” → “R” → “P”. 5) Stabilize the engine speed at idle. 6) Read the data of «Actual secondary pressure» using Subaru Select Monitor. CHECK INPUT SIGNAL FOR TCM. 1) Shift the select lever to “P” range. 2) Keep the engine speed at 3,000 rpm. 3) Read the data of «Actual secondary pressure» using Subaru Select Monitor.

Yes Go to step 11.

Is the «Actual secondary pres- Go to step 12. sure» 0.5 — 1.5 MPa?

Is the «Actual secondary pres- Go to step 13. sure» 1.5 — 2.5 MPa? And is the difference of the actual oil pressure 0.2 MPa or more compared with the value measured in step 11? CHECK TCM INPUT SIGNAL (STALL TEST). Is the «Actual secondary pres- Replace the trans1) Lift up the vehicle. sure» 4.5 — 6.0 MPa? mission assembly. 2) Start the engine.

6) Slowly open the accelerator fully, and stabilize the engine speed. 7) Read the data of «Actual secondary pressure» using Subaru Select Monitor. CHECK TCM INPUT SIGNAL (STALL TEST). Is the «Actual secondary pres- Replace the transCheck the «Actual Secondary Pressure» in sure» 4.5 MPa or less? mission assembly. step 13.

CVT(diag)-51

No Adjust the amount of ATF. Go to step 11. Replace the secondary pressure sensor.

Replace the secondary pressure sensor. Go to step 14.

Replace the control valve body.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

K: DTC P0842 SECONDARY OIL PRESSURE SENSOR CIRCUIT (LOW) DTC DETECTING CONDITION: Input signal circuit of secondary pressure sensor is open or shorted. TROUBLE SYMPTOM: Shift characteristics malfunction WIRING DIAGRAM: TCM

AT6

B54

2 17 15

1 2 3

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

17 14 18

B11 T4

1 2 3

B54 1 2 3 4 5 6 7 8 9 10 11 12 13

AT6

14 15 16 17 18 19 20 21 22 23 24 25 26

SECONDARY PRESSURE SENSOR

1

2

3

AT-05090

Step CHECK INPUT SIGNAL FOR TCM. 1) Start the engine. 2) Warm up until the ATF temperature reaches to 40 — 70°C (104 — 158°F). 3) Shift the select lever to “P” range. 4) Stabilize the engine speed at idle. 5) Read the data of “Actual secondary pressure” using Subaru Select Monitor. CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 2 — (B11) No. 17: (B54) No. 15 — (B11) No. 18: (B54) No. 17 — (B11) No. 14: CHECK HARNESS. Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 2 — Chassis ground: (B54) No. 17 — Chassis ground:

Check Yes No Is “Actual secondary pressure” Check for poor Go to step 2. 0.5 — 1.5 MPa? contact of connector.

Is the resistance less than 1 Ω? Go to step 3.

Repair the open circuit of harness.

Go to step 4.

Repair the short circuit of harness.

Is the resistance 1 MΩ or more?

CVT(diag)-52

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

4

5

6

Step CHECK TRANSMISSION HARNESS. 1) Disconnect the secondary pressure sensor connector. 2) Measure the resistance between transmission connector and secondary pressure sensor connector. Connector & terminal (T4) No. 14 — (AT6) No. 2: (T4) No. 17 — (AT6) No. 1: (T4) No. 18 — (AT6) No. 3: CHECK TRANSMISSION HARNESS. Measure the resistance between transmission connector and chassis ground. Connector & terminal (T4) No. 14 — Chassis ground: (T4) No. 17 — Chassis ground: CHECK SENSOR POWER SUPPLY. 1) Connect the connectors of TCM and transmission. 2) Turn the ignition switch to ON. 3) Measure the voltage between secondary pressure sensor connector terminals. Connector & terminal (AT6) No. 1 (+) — (AT6) No. 3 (–):

Check Yes Is the resistance less than 1 Ω? Go to step 5.

No Repair the open circuit of harness.

Is the resistance 1 MΩ or more?

Go to step 6.

Repair the short circuit of harness.

Is the voltage 4.5 V or more?

Replace the secondary pressure sensor.

Check for poor contact of the connector, and repair the fault location.

CVT(diag)-53

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

L: DTC P0843 SECONDARY OIL PRESSURE SENSOR CIRCUIT (HIGH) DTC DETECTING CONDITION: Input signal circuit of secondary pressure sensor is shorted. TROUBLE SYMPTOM: Shift characteristics malfunction WIRING DIAGRAM: TCM

AT6

B54

2 17 15

1 2 3

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

17 14 18

B11 T4

1 2 3

B54 1 2 3 4 5 6 7 8 9 10 11 12 13

AT6

14 15 16 17 18 19 20 21 22 23 24 25 26

SECONDARY PRESSURE SENSOR

1

2

3

AT-05090

Step CHECK INPUT SIGNAL FOR TCM. 1) Start the engine. 2) Warm up until the ATF temperature reaches to 40 — 70°C (104 — 158°F). 3) Shift the select lever to “P” range. 4) Stabilize the engine speed at idle. 5) Read the data of “Actual secondary pressure” using Subaru Select Monitor. CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Turn the ignition switch to ON. 4) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 2 (+) — Chassis ground (–): (B54) No. 17 (+) — Chassis ground (–): CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Measure the resistance between TCM connector terminals. Connector & terminal (B54) No. 2 — (B54) No. 17:

Check Yes No Is “Actual secondary pressure” Check for poor Go to step 2. 0.5 — 1.5 MPa? contact of connector.

Is the voltage approx. 0 V?

Go to step 3.

Is the resistance less than 1 Ω? Repair the short circuit of harness.

CVT(diag)-54

Repair the short circuit of harness.

Go to step 4.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

4

5

6

Step Check CHECK TRANSMISSION HARNESS. Is the voltage approx. 0 V? 1) Disconnect the secondary pressure sensor connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (T4) No. 14 (+) — Chassis ground (–): (T4) No. 17 (+) — Chassis ground (–): CHECK TRANSMISSION HARNESS. Is the resistance less than 1 Ω? 1) Turn the ignition switch to OFF. 2) Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 14 — (T4) No. 17: CHECK SENSOR POWER SUPPLY. Is the voltage 4.5 V or more? 1) Connect the connectors of TCM and transmission. 2) Turn the ignition switch to ON. 3) Measure the voltage between secondary pressure sensor connector terminals. Connector & terminal (AT6) No. 1 (+) — (AT6) No. 3 (–):

CVT(diag)-55

Yes Go to step 5.

No Repair the short circuit of harness.

Repair the short circuit of harness.

Go to step 6.

Replace the secondary pressure sensor.

Check for poor contact of the connector, and repair the fault location.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

M: DTC P0890 AT SELF-SHUT RELAY DIAGNOSIS (LOW) DTC DETECTING CONDITION: • Power supply circuit of TCM is open or shorted. • Self shut relay malfunction TROUBLE SYMPTOM: Gear is not changed. WIRING DIAGRAM:

TO POWER SUPPLY CIRCUIT MB-44 M/B FUSE NO. 1 (B)

B55 1 2 3 4 5 6 7 8 9 10 11

4

2

12 13 14 15 16 17 18 19 20 21 22

B494 SELF-SHUT RELAY 1 2 3 4

3

22

2 B55

11

20

1

B494

TCM

AT-05556

1

2

Step Check Yes CHECK HARNESS. Is the resistance less than 1 Ω? Go to step 2. 1) Disconnect the TCM and self shut relay connectors. 2) Measure the resistance between TCM connector and self shut relay connector. Connector & terminal (B55) No. 20 — (B494) No. 1: (B55) No. 2 — (B494) No. 3: (B55) No. 11 — (B494) No. 3: (B55) No. 22 — (B494) No. 3: CHECK HARNESS. Is the resistance 1 MΩ or Go to step 3. Measure the resistance between TCM connec- more? tor and chassis ground. Connector & terminal (B55) No. 20 — Chassis ground: (B55) No. 2 — Chassis ground: (B55) No. 11 — Chassis ground: (B55) No. 22 — Chassis ground:

CVT(diag)-56

No Repair the open circuit of harness.

Repair the short circuit of harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

3

4

5

6

7

Step CHECK RELAY POWER SUPPLY. Measure the voltage between self shut relay connector and chassis ground. Connector & terminal (B494) No. 2 (+) — Chassis ground (–): (B494) No. 4 (+) — Chassis ground (–): CHECK SELF SHUT RELAY. Measure the resistance between self shut relay terminals. Connector & terminal (B494) No. 1 — (B494) No. 2: CHECK SELF SHUT RELAY. Measure the resistance between self shut relay terminals. Connector & terminal (B494) No. 3 — (B494) No. 4: CHECK INPUT SIGNAL FOR TCM. 1) Connect the connectors of TCM and self shut relay. 2) Read the data of “Battery voltage” using Subaru Select Monitor.

CHECK FOR POOR CONTACT.

Check Is the voltage 10 V or more?

Yes Go to step 4.

No Repair the open or short circuit of harness.

Is the resistance 110 — 140 Ω? Go to step 5.

Replace the self shut relay.

Go to step 6.

Replace the self shut relay.

Is the resistance 1 MΩ or more?

Is the “Battery voltage” 10 V or Current condition Go to step 7. more? is normal. Check for poor contact of the connector or harness, and repair the fault location. Is there poor contact of the self Repair the poor Check the TCM. shut relay circuit? contact.

CVT(diag)-57

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

N: DTC P0951 MANUAL SWITCH DTC DETECTING CONDITION: Input signal circuit of manual mode switch is open or shorted. TROUBLE SYMPTOM: Manual mode can not be set. WIRING DIAGRAM:

TCM

B116

4

B 55

7

1 2 3 4 5 6 7 8

SELECT LEVER

MANUAL MODE SWITCH

B116

B55

8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

E AT-05092

1

2

3

4

5

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the manual mode switch connector. 3) Measure the resistance between manual mode switch connector and chassis ground. Connector & terminal (B116) No. 8 — Chassis ground: CHECK MANUAL MODE SWITCH. Measure the resistance between manual mode switch terminals. Connector & terminal (B116) No. 7 — No. 8: CHECK MANUAL MODE SWITCH. 1) Shift the select lever to manual mode. 2) Measure the resistance between manual mode switch terminals. Connector & terminal (B116) No. 7 — No. 8: CHECK HARNESS. 1) Disconnect the TCM connector. 2) Measure the resistance between TCM connector and manual mode switch connector. Connector & terminal (B116) No. 7 — (B55) No. 4: CHECK HARNESS. Measure the resistance between manual mode switch connector and chassis ground. Connector & terminal (B116) No. 7 — Chassis ground:

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness.

Go to step 3.

Replace the select lever assembly.

Is the resistance less than 1 Ω? Go to step 4.

Replace the select lever assembly.

Is the resistance less than 1 Ω? Go to step 5.

Repair the open circuit of harness or poor contact of connector.

Go to step 6.

Repair the short circuit of harness.

Is the resistance 1 MΩ or more?

Is the resistance 1 MΩ or more?

CVT(diag)-58

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

6

7

Step CHECK INPUT SIGNAL FOR TCM. 1) Connect the TCM and manual mode switch connector. 2) Turn the ignition switch to ON. 3) Set the select lever to the “D” range. 4) Read the “Manual Mode Switch” data using the Subaru Select Monitor. CHECK FOR POOR CONTACT.

Check Yes Does “Manual Mode Switch” Current condition display “ON” with select lever in is normal. manual mode, and “OFF” with select lever in other than manual mode?

No Go to step 7.

Is there poor contact of the manual mode switch circuit?

Check the TCM.

CVT(diag)-59

Repair the poor contact.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

O: DTC P0962 SECONDARY SOLENOID CIRCUIT (LOW) DTC DETECTING CONDITION: Output signal circuit of secondary solenoid is shorted. TROUBLE SYMPTOM: • Engine speed increases abruptly, and can not start. • Engine speed increases abruptly during driving. WIRING DIAGRAM: T11

TCM

12

B54

1

2

3

4

5

6

7

8

B11

5

B11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

1

5

T11

SECONDARY SOLENOID

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK INPUT SIGNAL FOR TCM. 1) After driving with warm up condition, park the vehicle while depressing the brake at “N” range. 2) Read the data of “Sec. Sol. Set Current” and “Sec. Sol. Actual Current” using Subaru Select Monitor. CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 12 — Chassis ground: CHECK SECONDARY SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 5 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage.

AT-05093

Check Yes No Does the value of “Sec. Sol. Set Check for poor Go to step 2. Current” and “Sec. Sol. Actual contact of connecCurrent” almost correspond? tor.

Is the resistance 1 MΩ or more?

Go to step 3.

Is the resistance approx. 7 Ω? (when engine cold)

Check for poor Go to step 4. contact of the connector, and repair the fault location.

Is there any malfunction in har- Go to step 5. ness?

CVT(diag)-60

Repair the short circuit of harness.

Replace the transmission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

Step Check CHECK HARNESS INSIDE TRANSMISSION. Is the resistance 1 MΩ or 1) Disconnect the control valve body connec- more? tor. 2) Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 5 — Transmission body:

CVT(diag)-61

Yes No Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

P: DTC P0963 SECONDARY SOLENOID CIRCUIT (HIGH) DTC DETECTING CONDITION: • Output signal circuit of secondary solenoid is open or shorted. • Secondary solenoid has open circuit inside. TROUBLE SYMPTOM: • Engine speed increases abruptly, and can not start. • Engine speed increases abruptly during driving. WIRING DIAGRAM: T11

TCM

12

B54

1

2

3

4

5

6

7

8

B11

5

B11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

1

5

T11

SECONDARY SOLENOID

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK INPUT SIGNAL FOR TCM. 1) After driving with warm up condition, park the vehicle while depressing the brake at “N” range. 2) Read the data of “Sec. Sol. Set Current” and “Sec. Sol. Actual Current”using Subaru Select Monitor. CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 12 — (B11) No. 5: CHECK HARNESS. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 12 (+) — Chassis ground (–): CHECK SECONDARY SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 5 — Transmission body:

AT-05093

Check Yes No Go to step 2. Does the value of “Sec. Sol. Set Check for poor Current” and “Sec. Sol. Actual contact of connector. Current” almost correspond?

Is the resistance less than 1 Ω? Go to step 3.

Repair the open circuit of harness.

Is the voltage approx. 0 V?

Go to step 4.

Repair the short circuit of harness.

Is the resistance approx. 7 Ω? (when engine cold)

Check for poor Go to step 5. contact of the connector, and repair the fault location.

CVT(diag)-62

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

6

Step Check CHECK HARNESS INSIDE TRANSMISSION. Is there any malfunction in harness? CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage. CHECK HARNESS INSIDE TRANSMISSION. Is the voltage approx. 0 V? 1) Disconnect the control valve body connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and transmission body. Connector & terminal (T4) No. 5 (+) — Transmission body (–):

CVT(diag)-63

Yes Go to step 6.

No Replace the transmission harness.

Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

Q: DTC P0965 FORWARD & REVERSE SOLENOID FUNCTION DTC DETECTING CONDITION: • Control valve hydraulic circuit malfunction • F&R solenoid characteristics malfunction • Clutch slippage caused by forward clutch facing deterioration • Clutch slippage caused by hydraulic pressure leaks TROUBLE SYMPTOM: • Engine speed increases abruptly, and can not accelerate. • Excessive slippage is felt. Step CHECK TRANSMISSION FLUID. Check the condition of ATF.

Check Is the ATF OK?

Yes Go to step 2.

2

CHECK TRANSMISSION FLUID. Check the amount of ATF.

Is the ATF amount correct?

Go to step 3.

3

CHECK INPUT SIGNAL FOR TCM. Is “Actual secondary pressure” Go to step 4. 1) Start the engine. 0.5 — 1.5 MPa? 2) Warm up until the ATF temperature reaches to 40 — 70°C (104 — 158°F). 3) Shift the select lever to “P” range. 4) Stabilize the engine speed at idle. 5) Read the data of “Actual secondary pressure” using Subaru Select Monitor. STALL TEST. Is the stall test normal? Go to step 5. Perform the stall test.

1

4

5

DRIVING CHECK BY INSPECTION MODE. Does the AT OIL TEMP light 1) Turn the ignition switch to OFF. blink and is DTC P0965 dis2) Perform a drive check based on the “Inspec- played? tion Mode”.

CVT(diag)-64

No Check according to the “corrective action” of ATF (CVTF) “CONDITION CHECK”.

Adjust the amount of ATF. Perform the diagnosis according to DTC P0841 procedure.

If the engine speed increases abruptly, replace the transmission assembly.

Replace the trans- If there is abrupt mission assembly. increase of engine

mission assembly. If it is normal, temporary poor contact occurs.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

R: DTC P0966 FORWARD & REVERSE SOLENOID CIRCUIT (LOW) DTC DETECTING CONDITION: Output signal circuit of F&R solenoid is shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM: T11

TCM

11

B54

1

2

3

4

5

6

7

8

B11

9

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

3

T4

5

T11 B54 F&R SOLENOID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK INPUT SIGNAL FOR TCM. 1) After driving with warm up condition, park the vehicle while depressing the brake at “D” range. 2) Read the data of “Commanded Forward & Reverse Linear Solenoid Current” and “Actual Forward & Reverse Linear Solenoid Current” using Subaru Select Monitor. CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 11 — Chassis ground: CHECK F&R SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 9 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage.

AT-05094

Check Yes No Does the value of “ComCheck for poor Go to step 2. manded Forward & Reverse contact of connecLinear Solenoid Current” and tor. “Actual Forward & Reverse Linear Solenoid Current” almost correspond?

Is the resistance 1 MΩ or more?

Go to step 3.

Is the resistance approx. 6 Ω? (when engine cold)

Check for poor Go to step 4. contact of the connector, and repair the fault location.

Is there any malfunction in har- Go to step 5. ness?

CVT(diag)-65

Repair the short circuit of harness.

Replace the transmission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

Step Check CHECK HARNESS INSIDE TRANSMISSION. Is the resistance 1 MΩ or 1) Disconnect the control valve body connec- more? tor. 2) Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 9 — Transmission body:

CVT(diag)-66

Yes No Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

S: DTC P0967 FORWARD & REVERSE LINEAR SOLENOID CIRCUIT (HIGH) DTC DETECTING CONDITION: • Output signal circuit of F&R solenoid is open or shorted. • F&R solenoid has open circuit inside. TROUBLE SYMPTOM: Engine speed increases abruptly, and can not start. WIRING DIAGRAM: T11

TCM

11

B54

1

2

3

4

5

6

7

8

B11

9

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

3

T4

5

T11 B54 F&R SOLENOID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK INPUT SIGNAL FOR TCM. 1) After driving with warm up condition, park the vehicle while depressing the brake at “D” range. 2) Read the data of “Commanded Forward & Reverse Linear Solenoid Current” and “Actual Forward & Reverse Linear Solenoid Current” using Subaru Select Monitor. CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 11 — (B11) No. 9: CHECK HARNESS. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 11 (+) — Chassis ground (–): CHECK F&R SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 9 — Transmission body:

AT-05094

Check Yes No Does the value of “ComCheck for poor Go to step 2. manded Forward & Reverse contact of connecLinear Solenoid Current” and tor. “Actual Forward & Reverse Linear Solenoid Current” almost correspond?

Is the resistance less than 1 Ω? Go to step 3.

Repair the open circuit of harness.

Is the voltage approx. 0 V?

Go to step 4.

Repair the short circuit of harness.

Is the resistance approx. 6 Ω? (when engine cold)

Check for poor Go to step 5. contact of the connector, and repair the fault location.

CVT(diag)-67

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

6

Step Check CHECK HARNESS INSIDE TRANSMISSION. Is there any malfunction in harness? CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage. CHECK HARNESS INSIDE TRANSMISSION. Is the voltage approx. 0 V? 1) Disconnect the control valve body connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and transmission body. Connector & terminal (T4) No. 9 (+) — Transmission body (–):

CVT(diag)-68

Yes Go to step 6.

No Replace the transmission harness.

Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

T: DTC P0970 TRANSFER SOLENOID CIRCUIT (LOW) DTC DETECTING CONDITION: Output signal circuit of AWD solenoid is shorted. TROUBLE SYMPTOM: Drivability getting worse. WIRING DIAGRAM: T11

TCM

13

B54

1

2

3

4

5

6

7

8

B11

4

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

8

T4

5

T11 B54 AWD SOLENOID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 13 — Chassis ground: CHECK AWD SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 4 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage. CHECK HARNESS INSIDE TRANSMISSION. 1) Disconnect the control valve body connector. 2) Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 4 — Transmission body:

AT-05098

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

Is the resistance approx. 4 Ω? (when engine cold)

Check for poor Go to step 3. contact of the connector, and repair the fault location.

Is there any malfunction in har- Go to step 4. ness?

Is the resistance 1 MΩ or more?

CVT(diag)-69

No Repair the short circuit of harness.

Replace the transmission harness.

Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

U: DTC P0971 TRANSFER SOLENOID CIRCUIT (HIGH) DTC DETECTING CONDITION: • Output signal circuit of AWD solenoid is open or shorted. • AWD solenoid has open circuit inside. TROUBLE SYMPTOM: • Tight corner braking phenomenon occurs. • Drivability getting worse. WIRING DIAGRAM: T11

TCM

13

B54

1

2

3

4

5

6

7

8

B11

4

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

8

T4

5

T11 B54 AWD SOLENOID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 13 — (B11) No. 4: CHECK HARNESS. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 13 (+) — Chassis ground (–): CHECK AWD SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 4 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage.

AT-05098

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness.

Is the voltage approx. 0 V?

Go to step 3.

Repair the short circuit of harness.

Is the resistance approx. 4 Ω? (when engine cold)

Check for poor Go to step 4. contact of the connector, and repair the fault location.

Is there any malfunction in har- Go to step 5. ness?

CVT(diag)-70

Replace the transmission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

Step Check CHECK HARNESS INSIDE TRANSMISSION. Is the voltage approx. 0 V? 1) Disconnect the control valve body connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and transmission body. Connector & terminal (T4) No. 4 (+) — Transmission body (–):

CVT(diag)-71

Yes No Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

V: DTC P0973 PRIMARY SOLENOID SYSTEM A CIRCUIT (LOW) DTC DETECTING CONDITION: Output signal circuit of primary UP solenoid is shorted. TROUBLE SYMPTOM: Gear is not changed. (No up-shift) WIRING DIAGRAM: T11

TCM

24

B54

1

2

3

4

5

6

7

8

B11

6

B11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

7

5

T11

PRIMARY UP SOLENOID

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 24 — Chassis ground: CHECK PRIMARY UP SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 6 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage. CHECK HARNESS INSIDE TRANSMISSION. 1) Disconnect the control valve body connector. 2) Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 6 — Transmission body:

AT-05099

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit of harness.

Is the resistance approx. 13 Ω? Check for poor Go to step 3. (when engine cold) contact of the connector, and repair the fault location. Is there any malfunction in har- Go to step 4. ness?

Is the resistance 1 MΩ or more?

CVT(diag)-72

Replace the transmission harness.

Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

W: DTC P0974 PRIMARY SOLENOID SYSTEM A CIRCUIT (HIGH) DTC DETECTING CONDITION: Output signal circuit of primary UP solenoid is open or shorted. TROUBLE SYMPTOM: Gear is not changed. (No up-shift) WIRING DIAGRAM: T11

TCM

24

B54

1

2

3

4

5

6

7

8

B11

6

B11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

7

5

T11

PRIMARY UP SOLENOID

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 24 — (B11) No. 6: CHECK HARNESS. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 24 (+) — Chassis ground (–): CHECK PRIMARY UP SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 6 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage.

AT-05099

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness.

Go to step 3.

Repair the short circuit of harness.

Is the voltage approx. 0 V?

Is the resistance approx. 13 Ω? Check for poor Go to step 4. (when engine cold) contact of the connector, and repair the fault location. Is there any malfunction in har- Go to step 5. ness?

CVT(diag)-73

Replace the transmission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

Step Check CHECK HARNESS INSIDE TRANSMISSION. Is the voltage approx. 0 V? 1) Disconnect the control valve body connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and transmission body. Connector & terminal (T4) No. 6 (+) — Transmission body (–):

CVT(diag)-74

Yes No Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

X: DTC P0976 PRIMARY SOLENOID SYSTEM B CIRCUIT (LOW) DTC DETECTING CONDITION: Output signal circuit of primary DOWN solenoid is shorted. TROUBLE SYMPTOM: Gear is not changed. (No down-shift) WIRING DIAGRAM: T11

TCM

25

B54

1

2

3

4

5

6

7

8

B11

1

B11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

6

5

T11

PRIMARY DOWN SOLENOID

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 25 — Chassis ground: CHECK PRIMARY DOWN SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 1 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage. CHECK HARNESS INSIDE TRANSMISSION. 1) Disconnect the control valve body connector. 2) Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 1 — Transmission body:

AT-05100

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit of harness.

Is the resistance approx. 13 Ω? Check for poor Go to step 3. (when engine cold) contact of the connector, and repair the fault location. Is there any malfunction in har- Go to step 4. ness?

Is the resistance 1 MΩ or more?

CVT(diag)-75

Replace the transmission harness.

Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

Y: DTC P0977 PRIMARY SOLENOID SYSTEM B CIRCUIT (HIGH) DTC DETECTING CONDITION: Output signal circuit of primary DOWN solenoid is open or shorted. TROUBLE SYMPTOM: Gear is not changed. (No down-shift) WIRING DIAGRAM: T11

TCM

25

B54

1

2

3

4

5

6

7

8

B11

1

B11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

6

5

T11

PRIMARY DOWN SOLENOID

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 25 — (B11) No. 1: CHECK HARNESS. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 25 (+) — Chassis ground (–): CHECK PRIMARY DOWN SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 1 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage.

AT-05100

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness.

Go to step 3.

Repair the short circuit of harness.

Is the voltage approx. 0 V?

Is the resistance approx. 13 Ω? Check for poor Go to step 4. (when engine cold) contact of the connector, and repair the fault location. Is there any malfunction in har- Go to step 5. ness?

CVT(diag)-76

Replace the transmission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

Step Check CHECK HARNESS INSIDE TRANSMISSION. Is the voltage approx. 0 V? 1) Disconnect the control valve body connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and transmission body. Connector & terminal (T4) No. 1 (+) — Transmission body (–):

Yes No Replace the con- Replace the transtrol valve body. mission harness.

Z: DTC P1718 AT CAN COMMUNICATION CIRCUIT NOTE: For DTC P1718 AT CAN communication circuit, refer to “LAN System”.

CVT(diag)-77

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

AA:DTC P1724 AT EEPROM ERROR DTC DETECTING CONDITION: • TCM EEPROM malfunction • EEPROM writing error during self shut control TROUBLE SYMPTOM: • AT learning is not finished. • Shock occurs when selecting N → D, N → R.

2

CHECK SELF SHUT RELAY. Turn the ignition switch to ON.

Check Yes Is the connection of TCM con- Go to step 2. nector correct? Does the relay operates simul- Go to step 3. taneously?

3

CHECK SELF SHUT RELAY. Turn the ignition switch to OFF.

Does the relay operate after two or three seconds delay?

Go to step 4.

4

PERFORM AT LEARNING. 1) Perform the {Clear Memories 2}. 2) Perform the AT learning. 3) Start the engine. CHECK INDICATION OF DTC. 1) Perform the {Clear Memory}. 2) Turn the ignition switch to OFF. 3) Start the engine after 10 seconds. 4) Repeat steps 2) and 3).

Does the AT OIL TEMP light blink after AT learning is finished correctly?

Check the TCM.

Does the AT OIL TEMP light blink and is DTC P1724 displayed?

Check the TCM.

1

5

Step CHECK TCM CONNECTOR.

No Connect the TCM connector. Perform the diagnosis according to DTC P0890 procedure. Perform the diagnosis according to DTC P0890 procedure. Go to step 5.

Current condition is normal. Check for poor contact of TCM connector or harness.

AB:DTC P1725 AT BODY SYSTEM CAN COMMUNICATION TROUBLE NOTE: DTC P1725 AT BODY SYSTEM CAN COMMUNICATION TROUBLE, refer to “LAN System”.

CVT(diag)-78

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

AC:DTC P2746 PRIMARY PULLEY REVOLUTION SPEED SENSOR CIRCUIT DTC DETECTING CONDITION: • Output signal circuit of primary speed sensor is open or shorted. • Primary speed sensor malfunction TROUBLE SYMPTOM: • Standing start problems • Shock occurs when engaging the lockup clutch. • Neutral control does not operate. WIRING DIAGRAM:

AT1

B54

TCM

6 1

1 2 3 TO POWER SUPPLY CIRCUIT

No. 38 7.5A

2 M/B

B12

B12

T3

1 2 3 4 5 6 7 8 9 10 11 12

5 6 7

1

1 2 3

MB-44 M/B FUSE NO. 1 (IG)

B54

AT1

14 15 16 17 18 19 20 21 22 23 24 25 26

1 2 3 4 5 6 7 8 9 10 11 12 13

PRIMARY SPEED SENSOR

AT-05104

1

2

3

Step CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse (No. 38).

Check Is the fuse OK?

Yes Go to step 2.

CHECK HARNESS. Is the resistance less than 1 Ω? Go to step 3. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 1 — (B12) No. 7: (B54) No. 6 — (B12) No. 6: (M/B No. 38) No. 2 — (B12) No. 5: CHECK HARNESS. Is the resistance 1 MΩ or Go to step 4. Measure the resistance between TCM connec- more? tor and chassis ground. Connector & terminal (B12) No. 5 — Chassis ground: (B12) No. 6 — Chassis ground:

CVT(diag)-79

No Replace the fuse. If the fuse blows out easily, repair the short circuit of harness. Repair the open circuit of harness.

Repair the short circuit of harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

4

5

6

Step CHECK TRANSMISSION HARNESS. 1) Connect the TCM connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B12) No. 6 (+) — Chassis ground (–): NOTE: Delete the TCM memory after completing the CVT control system diagnosis. CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to OFF. 2) Connect the transmission connector. 3) Lift up the vehicle. 4) Start the engine. 5) Slowly increase the speed to 30 km/h (18 MPH). 6) Read the data of “Primary Pulley Speed” using Subaru Select Monitor. CHECK TRANSMISSION HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the transmission connector. 3) Disconnect the primary speed sensor connector. 4) Measure the resistance between transmission connector and primary speed sensor connector. Connector & terminal (T3) No. 5 — (AT1) No. 1: (T3) No. 6 — (AT1) No. 2: (T3) No. 7 — (AT1) No. 3:

Check Is the voltage approx. 5 V?

Yes Go to step 5.

No Repair the open circuit of harness or poor contact of connector.

Does the value of “Primary Pul- Current condition Go to step 6. ley Speed” change according to is normal. Repair the engine speed? the poor contacts of harnesses of primary speed sensor and transmission connector.

Is the resistance less than 1 Ω? Replace the priReplace the transmary speed sen- mission harness. sor.

CVT(diag)-80

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

AD:DTC P2750 SEC. PULLEY REVOLUTION SPEED SENSOR CIRCUIT DTC DETECTING CONDITION: • Output signal circuit of secondary speed sensor is open or shorted. • Secondary speed sensor malfunction TROUBLE SYMPTOM: • Shock occurs when selecting N → D, N → R. • Neutral control does not operate. WIRING DIAGRAM:

AT4

B54

TCM

7 14

1 2 3

TO POWER SUPPLY CIRCUIT

No. 38 7.5A

1

B11

2 B11 M/B

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

11 10 20

MB-44 M/B FUSE NO. 1 (IG)

5

T4

3 2 1

B54 1 2 3 4 5 6 7 8 9 10 11 12 13

AT4

14 15 16 17 18 19 20 21 22 23 24 25 26

SECONDARY SPEED SENSOR

AT-05101

1

2

3

Step CHECK FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse (No. 38).

Check Is the fuse OK?

Yes Go to step 2.

CHECK HARNESS. Is the resistance less than 1 Ω? Go to step 3. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 7 — (B11) No. 10: (B54) No. 14 — (B11) No. 20: (M/B No. 38) No. 2 — (B11) No. 11: CHECK HARNESS. Is the resistance 1 MΩ or Go to step 4. Measure the resistance between TCM connec- more? tor and chassis ground. Connector & terminal (B11) No. 10 — Chassis ground: (B11) No. 11 — Chassis ground:

CVT(diag)-81

No Replace the fuse. If the fuse blows out easily, repair the short circuit of harness. Repair the open circuit of harness.

Repair the short circuit of harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

4

5

6

Step CHECK TRANSMISSION HARNESS. 1) Connect the TCM connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B11) No. 10 (+) — Chassis ground (–): NOTE: Delete the TCM memory after completing the CVT control system diagnosis. CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to OFF. 2) Connect the transmission connector. 3) Lift up the vehicle. 4) Start the engine. 5) Slowly increase the speed to 30 km/h (18 MPH). 6) Read the data of “Secondary Pulley Speed” using Subaru Select Monitor. CHECK TRANSMISSION HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the transmission connector. 3) Disconnect the secondary speed sensor connector. 4) Measure the resistance between transmission connector and secondary speed sensor connector. Connector & terminal (T4) No. 10 — (AT4) No. 2: (T4) No. 11 — (AT4) No. 3: (T4) No. 20 — (AT4) No. 1:

Check Is the voltage approx. 5 V?

Yes Go to step 5.

No Repair the open circuit of harness or poor contact of connector.

Does the value of “Secondary Current condition Go to step 6. Pulley Speed” change accord- is normal. Repair ing to the vehicle speed? the poor contacts of harnesses of secondary speed sensor and transmission connector.

Is the resistance less than 1 Ω? Replace the sec- Replace the transondary speed sen- mission harness. sor.

CVT(diag)-82

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

AE:DTC P2762 LOCK-UP DUTY SOLENOID MALFUNCTION DTC DETECTING CONDITION: • Lock up clutch malfunction • Hydraulic leaks or hydraulic valve stick of lock up system • Hydraulic leaks or hydraulic valve stick of lock up ON/OFF valve system • Lock up duty solenoid or lock up ON/OFF solenoid characteristics malfunction TROUBLE SYMPTOM: • No lock-up occurs. • Engine speed increases abruptly during driving. Step

1

2

3

4

5

6

Check Is DTC displayed?

Yes No CHECK DTC. Perform the diag- Go to step 2. Read the DTC relating the ECM using the Subnosis according to aru Select Monitor. DTC. CHECK DTC. Are DTC P0841, P0842, P0843 Perform the diag- Go to step 3. Read the DTC relating the TCM using the Sub- displayed? nosis according to aru Select Monitor. DTC. CHECK TRANSMISSION FLUID. Is the ATF OK? Go to step 4. Check according to Check the condition of ATF. action” of ATF (CVTF) “CONDITION CHECK”.

Is the ATF amount correct? Go to step 5. Adjust the amount CHECK TRANSMISSION FLUID. of ATF. CHECK INPUT SIGNAL FOR TCM. Is “Actual secondary pressure” Go to step 6. Perform the diag1) Lift up the vehicle. 0.5 — 1.5 MPa? nosis according to 2) Start the engine. DTC P0841 proce3) Warm up until the ATF temperature reaches dure. to 40 — 70°C (104 — 158°F). 4) Shift the select lever to “P” range. 5) Stabilize the engine speed at idle. 6) Read the data of “Actual secondary pressure” using Subaru Select Monitor. DRIVING CHECK FOR LOCK-UP CONDIDoes the AT OIL TEMP light Perform the secCurrent condition TION. blink and is DTC P2762 disondary pressure is normal. Tempo1) Perform the “Clear Memory Mode”. 3) Warm up until the ATF temperature exceeds When DTC other 50°C. than P2762 is dis4) Drive the vehicle for one minutes or more played, perform keeping the constant speed so that the display the diagnosis corshown in the Subaru Select Monitor is as folresponding to the lows: “Lock Up Duty Ratio” is 70 % or more, DTC. “Lock-Up ON/OFF Solenoid” is ON, “Front Wheel Speed” is 40 km/h or more. 5) Turn the ignition switch to OFF. 6) Start the engine. 7) Perform the procedure in step 4) again. 8) Read the DTC using Subaru Select Monitor.

CVT(diag)-83

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

AF:DTC P2763 LOCK-UP DUTY SOLENOID CIRCUIT (HIGH) DTC DETECTING CONDITION: Output signal circuit of lock-up duty solenoid is open or shorted. TROUBLE SYMPTOM: No lock-up occurs. WIRING DIAGRAM: T11

TCM

26

B54

1

2

3

4

5

6

7

8

B11

2

B11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

2

5

T11

LOCK-UP DUTY SOLENOID

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 26 — (B11) No. 2: CHECK HARNESS. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 26 (+) — Chassis ground (–): CHECK LOCK-UP DUTY SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 2 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage.

AT-05103

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness.

Go to step 3.

Repair the short circuit of harness.

Is the voltage approx. 0 V?

Is the resistance approx. 13 Ω? Check for poor Go to step 4. (when engine cold) contact of the connector, and repair the fault location. Is there any malfunction in har- Go to step 5. ness?

CVT(diag)-84

Replace the transmission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

Step Check CHECK HARNESS INSIDE TRANSMISSION. Is the voltage approx. 0 V? 1) Disconnect the control valve body connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and transmission body. Connector & terminal (T4) No. 2 (+) — Transmission body (–):

CVT(diag)-85

Yes No Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

AG:DTC P2764 LOCK-UP DUTY SOLENOID CIRCUIT (LOW) DTC DETECTING CONDITION: Output signal circuit of lock up duty solenoid is shorted. TROUBLE SYMPTOM: No lock-up occurs. WIRING DIAGRAM: T11

TCM

26

B54

1

2

3

4

5

6

7

8

B11

2

B11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

2

5

T11

LOCK-UP DUTY SOLENOID

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 26 — Chassis ground: CHECK LOCK-UP DUTY SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 2 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage. CHECK HARNESS INSIDE TRANSMISSION. 1) Disconnect the control valve body connector. 2) Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 2 — Transmission body:

AT-05103

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit of harness.

Is the resistance approx. 13 Ω? Check for poor Go to step 3. (when engine cold) contact of the connector, and repair the fault location. Is there any malfunction in har- Go to step 4. ness?

Is the resistance 1 MΩ or more?

CVT(diag)-86

Replace the transmission harness.

Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

AH:DTC P2769 LOCK-UP ON/OFF SOLENOID CIRCUIT (LOW) DTC DETECTING CONDITION: Output signal circuit of lock up ON/OFF solenoid is shorted. TROUBLE SYMPTOM: No lock-up occurs. WIRING DIAGRAM: T11

TCM

23

B54

1

2

3

4

5

6

7

8

B11

3

B11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

5

5

T11

LOCK-UP ON/OFF SOLENOID

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 23 — Chassis ground: CHECK LOCK UP ON/OFF SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 3 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage. CHECK HARNESS INSIDE TRANSMISSION. 1) Disconnect the control valve body connector. 2) Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 3 — Transmission body:

AT-05102

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit of harness.

Is the resistance approx. 17 Ω? Check for poor Go to step 3. (when engine cold) contact of the connector, and repair the fault location. Is there any malfunction in har- Go to step 4. ness?

Is the resistance 1 MΩ or more?

CVT(diag)-87

Replace the transmission harness.

Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

AI: DTC P2770 LOCK-UP ON/OFF SOLENOID CIRCUIT (HIGH) DTC DETECTING CONDITION: Output signal circuit of lock-up duty solenoid is open or shorted. TROUBLE SYMPTOM: No lock-up occurs. WIRING DIAGRAM: T11

TCM

23

B54

1

2

3

4

5

6

7

8

B11

3

B11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

5

5

T11

LOCK-UP ON/OFF SOLENOID

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

CONTROL VALVE BODY

1

2

3

4

Step CHECK HARNESS. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and transmission connectors. 3) Measure the resistance between TCM connector and transmission connectors. Connector & terminal (B54) No. 23 — (B11) No. 3: CHECK HARNESS. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 23 (+) — Chassis ground (–): CHECK LOCK UP ON/OFF SOLENOID. Measure the resistance between transmission connector and transmission body. Connector & terminal (T4) No. 3 — Transmission body: CHECK HARNESS INSIDE TRANSMISSION. CAUTION: Start work after ATF cools down. 1) Remove the transmission oil pan. 2) Check for the harness pinch, damage.

AT-05102

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness.

Go to step 3.

Repair the short circuit of harness.

Is the voltage approx. 0 V?

Is the resistance approx. 17 Ω? Check for poor Go to step 4. (when engine cold) contact of the connector, and repair the fault location. Is there any malfunction in har- Go to step 5. ness?

CVT(diag)-88

Replace the transmission harness.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

5

Step Check CHECK HARNESS INSIDE TRANSMISSION. Is the voltage approx. 0 V? 1) Disconnect the control valve body connector. 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and transmission body. Connector & terminal (T4) No. 3 (+) — Transmission body (–):

CVT(diag)-89

Yes No Replace the con- Replace the transtrol valve body. mission harness.

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Diagnostic Procedure without Diagnostic Trouble Code (DTC) CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

17.Diagnostic Procedure without Diagnostic Trouble Code (DTC) A: CHECK SHIFT INDICATOR DIAGNOSIS: • Output signal circuit of shift indicator is open or shorted. • Combination meter malfunction TROUBLE SYMPTOM: • Shift indicator does not display or remains displayed. • Shift indicator display does not change. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT FB-30 F/B FUSE NO. 5 (IG)

i10

19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

LCD SHIFT INDICATOR · SHIFT UP · SHIFT DOWN · SHIFT POSITION

I/F

COMBINATION METER

i10 MICRO COMPUTER

B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

17

32

18

33

CAN TRANSCEIVER & RECEIVER

B55

TCM

AT-05307

1

2

3

4

5

Step CHECK TCM. Check the DTC relating the TCM using the Subaru Select Monitor. CHECK TCM. Check the DTC relating the TCM using the Subaru Select Monitor. CHECK COMBINATION METER. Check the DTC of combination meter.

Check Yes Is only DTC P1725 displayed? Perform self diagnosis of the combination meter. Are DTCs other than P1725 Perform the diagdisplayed? nosis according to DTC. Is DTC displayed? Perform the diagnosis according to DTC. Is “1” displayed? Go to step 5.

CHECK TCM. 1) Turn the ignition switch OFF, then turn it ON again. 2) Shift the select lever to manual mode. 3) Read the “Shift step in Manu. mode” data using the Subaru Select Monitor. CHECK TCM. Is “2” displayed? 1) Shift up the select lever. 2) Read the “Shift step in Manu. mode” data using the Subaru Select Monitor.

CVT(diag)-90

No Go to step 2.

Go to step 3.

Go to step 4.

Perform the diagnosis according to DTC P0951.

Currently, shift indi- Check the TCM. cator is normal.

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Diagnostics with Phenomenon CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

18.Diagnostics with Phenomenon A: INSPECTION Symptoms Engine stalls when driving in “D” or “R” range, or selecting “N” → “D”, “N” → “R”. While driving in “D” range, vibration occurs immediately before the stop or engine stalls. Vehicle cannot shift while driving in “D” range.

Excessive shock when selecting “N” → “D”, and “N” → “R”.

Excessive shock at standing start in “D” range.

Engine speed increases abruptly during driving in “D” or “R” range.

Vehicle can not start when depressing the accelerator pedal in “D” or “R” range, or acceleration is very poor. (without abrupt engine increase)

Shift indicator in combination meter displays the position which differs from select lever position. Manual mode enters even though the select lever and paddle shift switch is not operated. Engine speed increases abruptly in “D” or “R” range, vehicle can not start. Manual mode can not be set

Problem parts • • • • • • • • • • • • • • • •

Control valve Engine control system Control valve Torque converter Control valve TCM Shift mechanism Power supply system Control valve TCM F&R clutch pack ATF deterioration or lack Control valve TCM F&R clutch pack ATF deterioration or lack

• • • •

Control valve Secondary pressure sensor F&R clutch pack ATF deterioration or lack

• • • • • • • • • • • • • • •

Control valve F&R clutch pack Shift mechanism Parking mechanism Engine control system Electronic parking brake system Power supply system Inhibitor switch Select cable related Combination meter Paddle shift switch Select lever TCM F&R clutch pack Select cable related

• Select lever • TCM

CVT(diag)-91

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Diagnostics with Phenomenon CONTINUOUSLY VARIABLE TRANSMISSION (DIAGNOSTICS)

CVT(diag)-92

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AUTOMATIC TRANSMISSION

5AT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

Page General Description ...................................................................................2 Automatic Transmission Fluid ..................................................................28 Differential Gear Oil ..................................................................................30 Road Test .................................................................................................31 Stall Test ..................................................................................................32 Time Lag Test ..........................................................................................33 Line Pressure Test ...................................................................................34 Transfer Clutch Pressure Test .................................................................36 Automatic Transmission Assembly ..........................................................38 Transmission Mounting System ...............................................................47 Extension Case Oil Seal ..........................................................................48 Differential Side Retainer Oil Seal ............................................................49 Inhibitor Switch .........................................................................................51 Front Vehicle Speed Sensor ....................................................................52 Rear Vehicle Speed Sensor .....................................................................54 Turbine Speed Sensor 1 ..........................................................................55 Control Valve Body ..................................................................................56 Transmission Control Module (TCM) .......................................................58 ATF Cooler Pipe and Hose ......................................................................59 Air Breather Hose .....................................................................................62 Oil Charge Pipe ........................................................................................63 Torque Converter Assembly ....................................................................64 Drive Plate ................................................................................................65 Extension Case ........................................................................................66 Transfer Clutch .........................................................................................68 Rear Drive Shaft .......................................................................................70 Reduction Driven Gear .............................................................................71 Center Differential Carrier ........................................................................74 Parking Pawl ............................................................................................76 Converter Case ........................................................................................78 Oil Pump Cover ........................................................................................80 Drive Pinion Shaft Assembly ....................................................................83 Front Differential Assembly ......................................................................88 AT Main Case ..........................................................................................93 Transmission Control Device .................................................................103 Diagnostics with Phenomenon ...............................................................105

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General Description AUTOMATIC TRANSMISSION

1. General Description A: SPECIFICATION 1. TORQUE CONVERTER CLUTCH Model Type Stall torque ratio Nominal diameter Stall speed (at sea level) One-way clutch

3.6 L non-turbo Symmetric, 3-element, single stage, 2-phase torque converter 1.8 246 mm (9.69 in) 2,100 — 2,600 rpm Sprague type one-way clutch

2. OIL PUMP Type Driving method Number of teeth

Internal gear fixed displacement pump Driven by engine Inner rotor Outer rotor

9 10

3. TRANSMISSION CONTROL ELEMENT 5-forward, 1-reverse, double-row planetary gears 3 sets 3 sets 2 sets

Type Multi-plate clutch Multi-plate brake One-way clutch (sprague type)

4. TRANSMISSION GEAR RATIO 1st 2nd 3rd 4th 5th Rev.

3.540 2.264 1.471 1.000 0.834 2.370

5. PLANETARY GEAR AND PLATE Model Number of front internal gear teeth Number of front carrier teeth Number of front sun gear teeth Number of mid internal gear teeth Number of mid carrier teeth Number of mid sun gear teeth Number of rear internal gear teeth Number of rear carrier teeth Number of rear sun gear teeth Number of front brake drive plates Number of input clutch drive plates Number of high & low reverse clutch drive plates

3.6 L non-turbo 106 28 50 78 18 42 110 24 62 2 6 4

Number of direct clutch drive plates Number of reverse brake drive plates Number of forward brake drive plates

5 5 5

5AT-2

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General Description AUTOMATIC TRANSMISSION

6. SELECTOR POSITION P (Park) R (Reverse) N (Neutral)

Transmission is in neutral, output member is immovable, engine start is possible Transmission is in reverse. Transmission is in neutral and engine start is possible Automatic gear change 1st ←→ 2nd ←→ 3rd ←→ 4th ←→ 5th Manual gear change 1st → 2nd → 3rd → 4th → 5th Manual gear change 1st ← 2nd ← 3rd ← 4th ← 5th Wire cable type

D (Drive) M (Manual mode), Paddle shift (+) M (Manual mode), Paddle shift (–) Control method

7. HYDRAULIC CONTROL AND LUBRICATION Electronic/hydraulic control [5 forward gear changes made by electronic signals of vehicle speed and accelerator (throttle) opening]

Type Recommended materials Fluid

Fluid capacity Lubrication system

SUBARU ATF HP

Idemitsu “ATF HP” CAUTION: Alternative Be sure to use the recommended or equivalent ATF. Using material except recommended one or substitute would cause trouble. 2 (US qt, Imp qt) 9.6 — 10.0 (10.1 — 10.6, 8.4 — 8.8) Forced feed lubrication with oil pump

8. COOLING AND HARNESS Cooling system Transmission harness

Liquid-cooler incorporated in radiator 20 + 8 poles

9. TRANSFER Transfer type Number of transfer clutch drives & driven plates

Variable torque distribution (VTD) 3

Reduction gear ratio

1.000 (41/41)

10.FINAL REDUCTION GEAR Model Front final reduction gear ratio

3.6 L non-turbo 3.083

5AT-3

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General Description AUTOMATIC TRANSMISSION

11.RECOMMENDED GEAR OIL

( C) ( F)

(1) (2) (3) GL-5 (4) -30 -26 -15 -5 0 -22 -15 5 23 32

15 59

25 30 77 86 90

Lubrication oil

85W 80W 75W -90 MT-00001

(1) Item (2) Front differential gear oil Front differential oil capacity

2 (US qt, Imp qt)

(3) API standard (4) SAE viscosity No. and applicable temperature

1.3 — 1.5 (1.4 — 1.6, 1.1 — 1.3)

5AT-4

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General Description AUTOMATIC TRANSMISSION

B: COMPONENT 1. TORQUE CONVERTER CLUTCH & TRANSMISSION ASSEMBLY

A (13) (17) (14) B

(17)

(18)

(23)

(30) T5 (29)

(22)

(19) (20)

T4 (21)

(34)

T6

T7

(15)

(4)

T4 (33) (32) (36)

(16) (5) (35) (8)

A

(1) (24)

(2)

T9

(3)

B

T1

T8 (6)

(7)

(27)

(37)

(28)

(26) T3

(25)

(9)

(31)

T4

T4 T2

(11) (10)

(12) AT-05545

5AT-5

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General Description AUTOMATIC TRANSMISSION (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Torque converter ASSY Circlip Oil pump shaft Differential oil level gauge Transmission hanger COMPL Differential oil drain plug Gasket Oil seal Lock plate Side retainer O-ring Oil seal ATF level gauge O-ring Oil charge pipe O-ring

(17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32)

Gasket Union screw Ball Spring Union screw ATF outlet pipe ATF inlet pipe Drive plate Reinforcement drive plate Oil pan Gasket ATF drain plug Breather hose Nipple O-ring Oil seal

5AT-6

(33) (34) (35) (36) (37)

Dust cover Floating bracket Turbine speed sensor 1 O-ring Magnet

Tightening torque:N·m (kgf-m, ft-lb) T1: 5 (0.5, 3.7) T2: 13 (1.3, 9.6) T3: 20 (2.0, 14.8) T4: 25 (2.5, 18.4) T5: 40 (4.1, 29.5) T6: 41 (4.2, 30.2) T7: 45 (4.6, 33.2) T8: 70 (7.1, 51.6) T9: 90 (9.2, 66.4)

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General Description AUTOMATIC TRANSMISSION

2. OIL PUMP & FRONT BRAKE

(9) (6)

(21) (7) (4) (3) (2) (1) (8) (5) T2 (18)

T1

(2)

(15) (20)

(14) (13)

(19)

(12) (11)

(17)

(10)

(16)

AT-05572

(1) (2) (3) (4) (5) (6) (7) (8) (9)

O-ring Washer Oil pump housing Oil pump rotor O-ring Air breather hose Oil pump cover O-ring Nipple

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Needle bearing D-ring (Inner) D-ring (Outer) Front brake piston Return spring Retainer Snap ring Driven plate Drive plate

5AT-7

(19) (20) (21)

Retaining plate Snap ring Stator shaft

Tightening torque:N·m (kgf-m, ft-lb) T1: 10 (1.0, 7.4) T2: 13 (1.3, 9.6)

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General Description AUTOMATIC TRANSMISSION

3. FRONT PLANETARY CARRIER AND MIDDLE & REAR PLANETARY CARRIER (5)

(4)

(3)

(2)

(9)

(1)

(20) (19) (18)

(8) (6)

(7) (17) (16) (15) (14) (13) (12) (11) (10)

AT-05573

(1) (2) (3) (4) (5) (6) (7)

Thrust bearing Front sun gear ASSY Snap ring Front carrier ASSY Race bearing O-ring Seal ring

(8) (9) (10) (11) (12) (13) (14)

Thrust bearing Input clutch ASSY Rear internal gear ASSY Thrust bearing Middle carrier ASSY Thrust bearing Race bearing

5AT-8

(15) (16) (17) (18) (19) (20)

Rear carrier ASSY Thrust bearing Middle & rear sun gear ASSY Washer Thrust bearing Seal ring

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General Description AUTOMATIC TRANSMISSION

4. DIRECT CLUTCH AND HIGH & LOW REVERSE CLUTCH

(3)

(2)

(1)

AT-02018

(1)

Thrust bearing

(2)

High & low reverse clutch ASSY

5AT-9

(3)

Direct clutch ASSY

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General Description AUTOMATIC TRANSMISSION

5. REVERSE BRAKE

(4)

(13) (3) (2) (1)

(5)

(12) (11) (10) (9) (8) (7) (6)

AT-05589

(1) (2) (3) (4) (5)

Snap ring Retaining plate Leaf spring Drive plate Driven plate

(6) (7) (8) (9) (10)

Dish plate Snap ring Retainer Return spring Reverse brake piston

5AT-10

(11) (12) (13)

D-ring (Outer) D-ring (Inner) AT main case

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General Description AUTOMATIC TRANSMISSION

6. SHORT AT ASSEMBLY

(1)

(4) (3) (2)

AT-04385

(1) (2)

Short AT assembly (non-disassembly) Thrust bearing

(3)

Seal ring

5AT-11

(4)

Thrust bearing

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General Description AUTOMATIC TRANSMISSION

7. CONTROL VALVE & TRANSMISSION HARNESS

(1) T (8)

T (3) (5) (6)

T

(2)

(8)

(9)

(4) T

(7)

AT-05574

(1) (2) (3) (4)

Rear vehicle speed sensor Transmission harness ASSY Front vehicle speed sensor Turbine speed sensor 1

(5) (6) (7) (8)

Harness bracket Clip Control valve ASSY O-ring

5AT-12

(9)

O-ring

Tightening torque:N·m (kgf-m, ft-lb) T: 7 (0.7, 5.2)

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General Description AUTOMATIC TRANSMISSION

8. DIFFERENTIAL GEAR

(1) (7) (13) (12) (14) (12) T1

(13) (8) (4) (2) (3)

(14)

(5) (6) (9)

T2 (10)

(1)

(11) (5) (3) (15)

T1 (4)

AT-03807

(1) (2) (3) (4) (5) (6) (7) (8)

Retainer lock plate Differential side retainer RH O-ring Oil seal Taper roller bearing Hypoid driven gear Drive pinion shaft Pinion shaft

(9) (10) (11) (12) (13) (14) (15)

Straight pin Differential case RH Differential case LH Differential bevel gear Washer Differential bevel pinion Differential side retainer LH

5AT-13

Tightening torque:N·m (kgf-m, ft-lb) T1: 25 (2.5, 18.4) T2: 70 (7.1, 51.6)

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General Description AUTOMATIC TRANSMISSION

9. TRANSFER CASE, EXTENSION CASE & REDUCTION GEAR (10) (14) (8)

(5)

(6)

(31)

(13) (30)

(5) (12) (11) (7)

(29) (28) (27)

(9) (26)

(4)

(25) (24)

(3) (23)

(2) (1)

(42)

(21) (22)

(41)

(19) (20)

T2

(18)

(40)

T1

(38)

(17)

(49)

(16)

T2 (15)

(37) (36)

(39)

(35) (34) (33)

(47)

T4

(45) (44) (48) (43)

(46)

(32)

T3 AT-05595

5AT-14

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General Description AUTOMATIC TRANSMISSION (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19)

Seal ring Reduction gear shim Ball bearing Snap ring Planetary pinion washer Needle bearing Spacer Pinion gear Planetary carrier ASSY Planetary pinion shaft ASSY Snap ring Thrust bearing Intermediate shaft Thrust washer Rear drive shaft Ball bearing Transfer clutch hub Transfer clutch plate Driven plate No. 3.

(20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38)

Ball bearing Rear drive shaft shim Revolution gear Snap ring Clutch spring retainer Return spring Spring retainer Pressure plate Ball bearing O-ring Transfer clutch piston D-ring Drive pinion shaft Ball bearing Reduction driven gear Snap ring Ball bearing Shim Gasket

5AT-15

(39) (40) (41) (42) (43) (44) (45) (46) (47) (48) (49)

Extension case Transmission hanger Oil seal Dust cover Taper roller bearing Drive pinion shim Oil seal Drive pinion collar O-ring Lock nut O-ring

Tightening torque:N·m (kgf-m, ft-lb) T1: 13 (1.3, 9.6) T2: 25 (2.5, 18.4) T3: 70 (7.1, 51.6) T4: 116 (11.8, 85.6)

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General Description AUTOMATIC TRANSMISSION

10.TRANSMISSION CONTROL DEVICE & PARKING SUPPORT (17) (16)

(15)

(1)

T3

(14)

T4

(13) (2)

(3) T5 (12)

(11) (10) (9)

(5)

(4) (18) T1

(8) (6)

(7)

T2

AT-05685

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Bracket Floating bracket AT main case Range select lever Straight pin Detent spring Manual plate Parking rod Parking support actuator

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Parking pawl shaft Return spring Parking pawl Ball bearing Snap ring Parking gear Reduction driven gear Ball bearing Gasket

5AT-16

Tightening torque:N·m (kgf-m, ft-lb) T1: 6 (0.6, 4.4) T2: 7 (0.7, 5.2) T3: 18 (1.8, 13.3) T4: 25 (2.5, 18.4) T5:

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General Description AUTOMATIC TRANSMISSION

11.TRANSMISSION CONTROL MODULE

T

(1)

(2)

AT-05557

(1)

Transmission control module (TCM)

(2)

Relay

Tightening torque:N·m (kgf-m, ft-lb) T: 7.5 (0.8, 5.5)

5AT-17

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General Description AUTOMATIC TRANSMISSION

12.TRANSMISSION MOUNTING

T2 (1)

T2

(2)

T4

T4 T3

(3) T3

(4)

T4

T1

(5) T4 AT-05568

(1)

Rear cushion rubber

(4)

Transmission main mounting bracket (RH)

(2)

Crossmember

(5)

Transmission main mounting bracket (LH)

(3)

Stopper

Tightening torque:N·m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 40 (4.1, 29.5) T3: 45 (4.6, 33.2) T4: 75 (7.6, 55.3)

5AT-18

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General Description AUTOMATIC TRANSMISSION

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Until the oil pan is removed, do not place with the oil pan side facing up to prevent foreign matter from entering the valve body. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, disassembly and replacement. • When disassembling the case and other light alloy parts, disassemble them by slightly tapping with a plastic hammer. Do not pry apart with screwdrivers or other tools. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Use SUBARU genuine gear oil, grease or equivalent. Do not mix them of different grades or manufacturers. • Be sure to tighten bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Apply gear oil onto sliding or revolving surfaces before installation. • Replace deformed or damaged snap rings with new parts. • Before installing O-rings or oil seals, apply sufficient amount of ATF fluid to avoid damage and deformation. • Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts. • Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. • Avoid damaging the mating surface of the case. • Before applying liquid gasket, completely remove the old liquid gasket.

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 498575400

DESCRIPTION OIL PRESSURE GAUGE ASSY

REMARKS Used for measuring oil pressure.

OIL PRESSURE ADAPTER

Used together with oil pump cover installed on when measuring line pressure.

ST-498575400

498897200

ST-498897200

5AT-19

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General Description AUTOMATIC TRANSMISSION ILLUSTRATION

TOOL NUMBER 498897800

DESCRIPTION OIL PRESSURE ADAPTER SET

REMARKS Used for measuring transfer clutch pressure.

498277200

STOPPER SET

• Used for removing and installing automatic transmission assembly to engine. • Used for preventing the torque converter from dropping off.

398527700

PULLER ASSY

• Used for removing the extension case roller bearing. • Used for removing the extension oil seal. • Used for removing the front differential side retainer bearing outer race. • Used for removing the front differential side retainer oil seal.

498057300

INSTALLER

Used for installing the extension oil seal.

498077000

REMOVER

Used for removing the differential taper roller bearing.

ST-498897800

ST-498277200

ST-398527700

ST-498057300

ST-498077000

5AT-20

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General Description AUTOMATIC TRANSMISSION ILLUSTRATION

TOOL NUMBER DESCRIPTION 18658AA020 WRENCH COMPL (Newly adopted tool) RETAINER

REMARKS • Used for removing and installing the differential side retainer. • Existing SST (18630AA010) with the handle removed. Use together with a commercially sold spinner handle. • WRENCH COMPL RETAINER (18630AA010) can also be used.

ST18658AA020

398487700

DRIFT

Used for installing the front differential taper roller bearing.

498255400

PLATE

Used for measuring the backlash of hypoid gear.

498247001

MAGNET BASE

• Used for measuring the gear backlash. • Used together with DIAL GAUGE (498247100).

498247100

DIAL GAUGE

• Used for measuring the gear backlash. • Used together with MAGNET BASE (498247001).

ST-398487700

ST-498255400

ST-498247001

ST-498247100

5AT-21

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General Description AUTOMATIC TRANSMISSION ILLUSTRATION

TOOL NUMBER 498517000

DESCRIPTION REPLACER

REMARKS Used for removing the front roller bearing.

499787700

WRENCH

Used for removing and installing the drive pinion lock nut.

398643600

GAUGE

Used for measuring total end play, extension end play and drive pinion height.

398744300

PISTON GUIDE

Used for measuring height from mating surface of the main case to pressure plate.

499737100

PULLER SET

Used for removing the reduction driven gear assembly.

ST-498517000

ST-499787700

ST-398643600

ST-398744300

ST-499737100

5AT-22

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General Description AUTOMATIC TRANSMISSION ILLUSTRATION

TOOL NUMBER 498077600

DESCRIPTION REMOVER

REMARKS Used for removing the ball bearing.

HOLDER

• Used for removing and installing the drive pinion lock nut. • Used as a handle to rotate gear when checking tooth contact.

SUBARU SELECT MONITOR III KIT

Used for troubleshooting the electrical system.

18675AA000

DIFFERENTIAL SIDE OIL SEAL INSTALLER

Used for installing the differential side retainer oil seal.

18654AA000

INSTALLER

Used for removing and installing the ball bearing.

ST-498077600

18667AA010

ST18667AA010

1B022XU0

ST1B022XU0

ST18675AA000

ST18654AA000

5AT-23

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General Description AUTOMATIC TRANSMISSION ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

28399SA010

OIL SEAL PROTEC- Used for protecting oil seal when installing front TOR drive shaft.

18763AA000

COMPRESSOR SHAFT

Used for disassembling multi-plate clutch for shift transmission.

18765AA000

COMPRESSOR SUPPORT

Used for disassembling multi-plate clutch for shift transmission.

18676AA020

TORX® WRENCH

Used for disassembling torque converter case.

18854AA000

ANGLE GAUGE

Used for tightening parking support.

ST28399SA010

ST18763AA000

ST18765AA000

ST18676AA020

ST18854AA000

5AT-24

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General Description AUTOMATIC TRANSMISSION ILLUSTRATION

TOOL NUMBER 498077300

DESCRIPTION REMOVER

REMARKS Used for removing ball bearing of reduction driven gear.

499587100

OIL SEAL INSTALLER

Used for installing the oil seal.

499787500

ADAPTER

Used for removing and installing drive pinion lock nut.

499575400

GAUGE

Used for measuring the height of total end play.

COMPRESSOR SPECIAL TOOL

Used for disassembling multi-plate clutch for shift transmission.

ST-498077300

ST-499587100

ST-499787500

ST-499575400

18762AA000

ST18762AA000

5AT-25

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General Description AUTOMATIC TRANSMISSION ILLUSTRATION

TOOL NUMBER 499755602

DESCRIPTION PRESS

REMARKS Used for installing the parking gear.

18680AA010

GEAR HOLDER

Used for removing reduction driven gear assembly. (2-piece set)

18766AA000

SUPPORT PULLER

Used for removing reduction driven gear assembly.

18767AA000

REMOVER

• Used to pull out the parking gear. • Used to pull out the bearing from the VTD assembly.

ST-499755602

ST18680AA010

ST18766AA000

ST18767AA000

41099AJ010 SPECIAL (Newly adopted tool) TOOL H6

ST41099AJ010

5AT-26

• Used for removing and installing transmission. • For H6 engine.

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General Description AUTOMATIC TRANSMISSION ILLUSTRATION

TOOL NUMBER DESCRIPTION 18360AA020 HANGER (Newly adopted tool)

REMARKS • Used for removing and installing transmission. • For H6 engine.

99099AJ000 SPECIAL (Newly adopted tool) TOOL ENGINE HANGER

• Used for removing and installing transmission. (Weight of 350 kg (772 lb) is supported) • Used together with SPECIAL TOOL CHAIN BALANCER (99099AJ010) and sling chain (general tool).

99099AJ010 SPECIAL (Newly adopted tool) TOOL CHAIN BALANCER

• Used for removing and installing transmission. (Weight of 350 kg (772 lb) is supported) • Used together with SPECIAL TOOL ENGINE HANGER (99099AJ000) and sling chain (general tool). • Used to hang the engine while balancing it with the sling chain inserted in this tool.

ST18360AA020

ST99099AJ000

ST99099AJ010

2. GENERAL TOOL TOOL NAME Depth gauge Thickness gauge Micrometer Spring scale Circuit tester TORX® T70 Snap ring pliers Sling chain

Screw shackle

REMARKS Used for measuring the transmission end play. Used for measuring clearance of the clutch, brake and oil pump. Used for measuring thickness of the drive pinion. Used for measuring the starting torque of the drive pinion. Used for measuring resistance and voltage. Used for removing and installing differential gear oil drain plug. Used for removing and installing each snap ring. Used for removing and installing transmission. • Length: 0.8 — 1 m (2.6 — 3.3 ft) • Load capacity: 1.2 t (2646 lb) or more • Diameter: 6 mm (0.24 in) or 6.3 mm (0.25 in) • Chain external width: 23.5 mm (0.93 in) or less • Chain internal width: 8.5 mm (0.33 in) or more Used for removing and installing transmission. • Load capacity: 250 kg (551 lb) or more • Use two pieces.

5AT-27

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Automatic Transmission Fluid AUTOMATIC TRANSMISSION

2. Automatic Transmission Fluid A: INSPECTION

(B)

F HOT

NOTE: The level of ATF varies with fluid temperature. Pay attention to the ATF temperature when checking ATF level. 1) Raise the ATF temperature by driving a distance of 5 to 10 km (3 to 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 — 80°C (158 — 176°F) on Subaru Select Monitor. 2) Park the vehicle on a level surface. 3) After selecting all positions (P, R, N, D), set the select lever in “P” range. Idle the engine for 1 to 2 minutes. 4) Remove the oil level gauge and wipe it clean. 5) Reinsert the level gauge all the way. Make sure the level gauge is inserted correctly and in the proper orientation. 6) Remove the oil level gauge again and make sure that the ATF level is between upper and lower marks of the HOT side.

B: REPLACEMENT 1) Lift up the vehicle. 2) Remove the ATF drain plug to drain ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself. 3) Check the ATF condition. 4) Tighten the ATF drain plug. NOTE: Use a new gasket.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (B)

(A) AT-05460

(C) F

L

(A) Oil pan (B) ATF drain plug

(B) COLD L

(A)

(C)

5) Lower the vehicle. 6) Pour ATF from the oil charge pipe.

Recommended fluid:

AT-04217

(A) ATF level gauge (B) Upper level (C) Lower level

7) If the ATF level is below the lower mark, add recommended ATF until the fluid level is between upper and lower marks. CAUTION: • Be careful not to exceed the upper level. • When the transmission is cold, be careful not to add ATF to the upper level on HOT side. Overfilling of ATF may cause oil splashing. 8) Check the ATF for leaks. Visually check for leaks in the transmission. If there are leaks, replace the gasket, oil seal, plug or other parts.

CAUTION: Be sure to use the recommended or equivalent ATF. Using material except recommended one or substitute would cause trouble.

Capacity: Fill with the same amount of ATF as drained. Capacity when transmission is overhauled: 9.6 — 10.0 2 (10.1 — 10.6 US qt, 8.4 — 8.8 Imp qt) 7) Check the level and leaks of ATF.

5AT-28

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Automatic Transmission Fluid AUTOMATIC TRANSMISSION

C: CONDITION CHECK NOTE: When replacing ATF, check the inside condition of transmission body by inspecting the drained ATF. Fluid condition Large amount of metallic pieces are found.

Internal metal parts of transmission body are excessively worn.

Trouble and possible cause

Replace ATF and check if AT operates correctly.

Is thick and is a varnish-form fluid.

Clutch etc. is burned.

Replace ATF and check the AT body or vehicle for faulty.

Clouded fluid or bubbles are found in fluid.

Water is mixed.

Replace ATF and check the water entering point.

5AT-29

Corrective action

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Differential Gear Oil AUTOMATIC TRANSMISSION

3. Differential Gear Oil

B: REPLACEMENT

A: INSPECTION

1) Lift up the vehicle. 2) Remove the differential gear oil drain plug using TORX® bit T70, and then drain differential gear oil.

1) Park the vehicle on a level surface. 2) Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. (1) Pull up the two points at the rear (A). (2) Pull up the two points at the front (B) while moving them forward.

(A)

(A)

CAUTION: • Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself. • Be careful not to spill differential gear oil on the exhaust pipe to prevent it from emitting smoke or causing a fire. If differential gear oil is spilled on the exhaust pipe, wipe it off completely. 3) Tighten the differential gear oil drain plug using TORX® bit T70. NOTE: Use a new gasket.

(B)

Tightening torque: 70 N·m (7.1 kgf-m, 51.6 ft-lb)

(B) ME-04447

3) Remove the oil level gauge and wipe it clean. 4) Reinsert the level gauge all the way. Make sure the level gauge is inserted correctly and in the proper orientation. 5) Remove the oil level gauge again, and check the level of differential gear oil. If the differential gear oil level is below “L” line, add oil to bring the level up to “F” line.

(A) (B)

NOTE: To prevent overfilling the differential gear oil, do not add oil above the “F” line.

AT-05473

(A) Oil pan (B) Differential gear oil drain plug

F

4) Lower the vehicle. 5) Pour gear oil into the level gauge hole. (A) L

(B)

AT-00017

(A) Upper level (B) Lower level

Recommended gear oil:

Gear oil capacity: 1.3 — 1.5 2 (1.4 — 1.6 US qt, 1.1 — 1.3 Imp qt) 6) Check the level of differential gear oil.

5AT-30

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Road Test AUTOMATIC TRANSMISSION

4. Road Test A: INSPECTION 1. GENERAL PRECAUTION Road tests should be conducted to properly diagnose the condition of automatic transmission. NOTE: When performing the test, do not exceed posted speed limit.

2. D RANGE SHIFT FUNCTION Check shifting between 1st ←→ 2nd ←→ 3rd ←→ 4th ←→ 5th while driving on normal city streets.

3. D RANGE SHIFT SHOCK Check the shock level when shifting up during normal driving.

4. KICK-DOWN FUNCTION Check kick-down for each gear. Check the shock level during kick-down at the same time.

5. ENGINE BRAKE OPERATION • Check the 4th gear engine brake when shifting down from 5th to 4th range while driving in 5th gear of manual mode [50 to 60 km/h (31 to 37 MPH)]. • Check the 3rd gear engine brake when shifting down from 4th to 3rd range while driving in 4th gear of manual mode [50 — 60 km/h (31 — 37 MPH)]. • Check the 2nd gear engine brake when shifting down from 3rd to 2nd range while driving in 3rd gear of manual mode [40 — 50 km/h (25 — 31 MPH)]. • Check the 1st gear engine brake when shifting down from 2nd to 1st range while driving in 2nd gear of manual mode [20 — 30 km/h (12 — 19 MPH)].

6. LOCK-UP FUNCTION When the accelerator is lightly depressed while driving on a flat road in lock-up range, check that rpm does not change abruptly.

7. P RANGE OPERATION Stop the vehicle on an uphill grade of 5% or more and shift to the “P” range. Check that the vehicle does not move when the parking brake is released.

8. NOISE AND VIBRATION Check for noise and vibration while driving and during shifting.

9. OIL LEAKAGE After the driving test, inspect for oil leaks from the transmission body.

5AT-31

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Stall Test AUTOMATIC TRANSMISSION

5. Stall Test

10) When the engine speed is stabilized, quickly record the engine speed and release accelerator pedal. 11) Shift the select lever to “N” range, and cool down the engine by idling it for one minute or more.

A: INSPECTION NOTE: The stall test is extremely important in diagnosing the condition of an automatic transmission and engine. The test is necessary to measure the engine stall speeds in “2nd gear of manual mode”. Purposes of the stall test: • Operational check of the automatic transmission clutch • Operational check of the torque converter clutch • Engine performance check 1) Check that the throttle valve fully opens. 2) Check that the engine oil level is correct. 3) Check that the coolant level is correct. 4) Check that the ATF level is correct. 5) Check that the differential gear oil level is correct. 6) Raise the ATF temperature to 70 to 80°C (158 to 176°F) by driving a distance of 5 to 10 km (3 to 6 miles). Confirm the ATF temperature on Subaru Select Monitor. 7) Place the wheel chocks at the front and rear of all wheels and apply the parking brake. 8) Move the select lever to ensure it operates properly, then set to “2nd gear of manual mode”. 9) While stepping hard on the brake pedal, gradually step on the accelerator pedal.

NOTE: • Do not perform a stall test for over 5 seconds at a time. (Perform with the throttle from fully closed to fully open to end up reading the stall speed.) Doing so will make the engine oil and ATF deteriorate and the clutch and brake to be adversely affected. • After performing the stall test, be sure to cool down the engine for at least one minute with the select lever set in “P” or “N” range, and at an idle speed of 1,200 rpm or less. • If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the automatic transmission from sustaining damage. • Perform the stall test in S mode. • When depressing the accelerator pedal again after performing the stall test for 5 seconds or more, the electronic throttle control remains closed for approx. 60 seconds. • When the stall test is performed for 15 seconds or more continuously, the test is completed forcibly to protect the transmission unit. When depressing the accelerator pedal again, the electronic throttle control remains closed for approx. 60 seconds.

Stall speed (at sea level): 2,100 — 2,600 rpm Stall speed (at sea level) Over specified value

Range

Possible faulty parts

2nd gear of manual mode

• • • •

Line pressure too low Forward brake Direct clutch 3rd one-way clutch

5AT-32

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Time Lag Test AUTOMATIC TRANSMISSION

6. Time Lag Test A: INSPECTION NOTE: When the select lever is shifted while the engine is idling, there will be a certain time elapse or lag before shock is felt. Using this, check the condition of forward brake, reverse brake, 1st one-way clutch and 3rd one-way clutch. • Perform the test at normal operation fluid temperature of 70 — 80°C (158 — 176°F). • Be sure to allow one minute or more interval between tests. • Make three measurements and take the average value. 1) Fully apply the parking brake. 2) Start the engine. Check the idling speed. (A/C OFF) 3) Shift the select lever from “N” to “D” range. Using a stop watch, measure the time-lag from shifting the lever until the shock is felt.

Time-lag Standard: 1.2 seconds or less If “N” → “D” time-lag is longer than specification: • Line pressure too low • Forward brake worn • One-way clutch not operating properly 4) In the same manner, measure the time lag of “N” → “R”. Time-lag Standard: 1.5 seconds or less If “N” → “R” time lag is longer than specification: • Line pressure too low • Reverse brake worn

5AT-33

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Line Pressure Test AUTOMATIC TRANSMISSION

7. Line Pressure Test A: MEASUREMENT NOTE: If the clutch or brake shows a sign of slippage, or shifting interval is not correct, check the line pressure. • Excessive shock during up-shift may be due to the line pressure being too high. • In many cases, slippage or inability to operate the vehicle may be due to insufficient oil pressure for the operation of clutch, brake or control valve. 1) Lift up the vehicle. 2) Remove the test plug and install the ST. ST 498897200 OIL PRESSURE ADAPTER

AT-05461

3) Set the ST1 and ST2. ST1 498897200 OIL PRESSURE ADAPTER ST2 498575400 OIL PRESSURE GAUGE ASSY 4) Lower the vehicle, and pull ST2, which were set in step 3), into the vehicle. 5) Connect the Subaru Select Monitor to the data link connector and read the current data.

5AT-34

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Line Pressure Test AUTOMATIC TRANSMISSION

6) Perform the line pressure test. NOTE: • Do not perform the line pressure test for 5 seconds or more at a time. Doing so will make the engine oil and ATF deteriorate and the clutch and brake to be adversely affected. • After performing the line pressure test, be sure to cool down the engine for at least one minute with the select lever set in “P” or “N” range and with the idle speed at 1,200 rpm or less. Range of the select lever

2nd gear of manual mode

R

Accelerator pedal opening angle

ATF temperature condition

“P/L Solenoid Pressure” displayed on the Subaru Select Monitor kPa

Standard line pressure kPa (kg/cm2, psi)

350 — 500

Target pressure (displayed on Subaru Select Monitor) –10 — +190 (Target pressure –0.10 — +1.94, Target pressure –1.45 — +27.5)

Full closed 45 — 55°C (113 — 131°F) Full open

2,000 or more

Full open

1,600 or more

7) Remove the ST and install the test plug.

Tightening torque: 13 N·m (1.3 kgf-m, 9.6 ft-lb)

5AT-35

1,320 — 1,520 (13.46 — 15.50, 191.4 — 220.4) 1,660 — 1,860 (16.93 — 18.97, 240.7 — 269.7)

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Transfer Clutch Pressure Test AUTOMATIC TRANSMISSION

8. Transfer Clutch Pressure Test A: INSPECTION 1) Lift up the vehicle. 2) Remove the bolts holding the heat shield cover, and move the heat shield cover to the rear. 3) Remove the test plug and install the ST. CAUTION: Be careful not to cut yourself on the heat shield cover when removing the test plugs and setting the ST. ST 498897800 OIL PRESSURE ADAPTER SET

AT-03275

4) Set the ST. ST 498575400

OIL PRESSURE GAUGE ASSY 5) Lower the vehicle, and pull ST, which were set in step 4), into the vehicle. 6) Connect the Subaru Select Monitor to the data link connector and read the current data.

5AT-36

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Transfer Clutch Pressure Test AUTOMATIC TRANSMISSION

7) Perform the transfer clutch pressure test. NOTE: • Do not perform the transfer clutch pressure test for 5 seconds or more at a time. Doing so will make the engine oil and ATF deteriorate and the clutch and brake to be adversely affected. • After performing the transfer clutch pressure test, be sure to cool down the engine for at least one minute with the select lever set in the “P” or “N” range, and at an idle speed of 1,200 rpm or less. • Adjust the accelerator pedal opening angle in order to obtain the “T/F solenoid target pressure” displayed on the Subaru Select Monitor. Range of the select lever

Accelerator pedal opening angle

2nd gear of manual mode

Partial throttle

N

Full closed

“T/F Solenoid Target Pressure” displayed on the Subaru Select Monitor kPa

ATF temperature condition

400

45 — 55°C (113 — 131°F)

0

8) Remove the ST and install the test plug.

Tightening torque: 13 N·m (1.3 kgf-m, 9.6 ft-lb) 9) Install the heat shield cover.

5AT-37

Standard transfer clutch pressure kPa (kg/cm2, psi) 300 — 500 (3.06 — 5.10, 43.5 — 72.5) 0 — 50 (0 — 0.51, 0 — 7.2)

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Automatic Transmission Assembly AUTOMATIC TRANSMISSION

9. Automatic Transmission Assembly

9) Disconnect the following connectors. (B)

A: REMOVAL 1) Set the vehicle on a lift. 2) Remove the front wheels. 3) Fully open the front hood. 4) Disconnect the ground cable from battery. 5) Remove the collector cover.

(A)

NOTE: Follow the steps below when removing the collector cover. (1) Pull up the two points at the rear (A). (2) Pull up the two points at the front (B) while moving them forward.

(A)

AT-05465

(A) Transmission harness connectors (B) Front oxygen (A/F) sensor

10) Disconnect the ground cable.

(A)

(B)

(B) ME-04447

AT-05558

6) Remove the air intake duct. 7) Remove the 10 clips and detach the grille bracket.

11) Remove the air breather hose. 12) Remove the starter. 13) Remove the engine hanger rear.

CO-02594

8) Remove the air intake boot.

AT-05466

14) Separate the torque converter from drive plate. CAUTION: • Be careful not to drop bolts into converter housing. • Be careful not to damage the mounting bolts. (1) Remove the service hole plug. (2) Remove the bolts which hold torque converter to drive plate. (3) Remove the four bolts by rotating the crank pulley a little at a time.

5AT-38

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Automatic Transmission Assembly AUTOMATIC TRANSMISSION

(4) Make sure the torque converter moves freely by rotating with finger through the starter installation hole.

20) Remove the heat shield cover.

AT-01331

21) Remove the steering shaft universal joint.

22) Remove the ATF drain plug to drain ATF.

AT-05467

15) Attach the ST to the converter case. ST 498277200 STOPPER SET

(B)

(A)

ST AT-05460 AT-00103

(A) Oil pan (B) ATF drain plug

16) Attach the ST to the engine.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) ST 18360AA020 HANGER

23) Remove the oil charge pipe.

ST AT-05468 AT-05498

17) Lift up the vehicle. 18) Remove the under cover. 19) Remove the front and rear exhaust pipes.

24) Disconnect the connector from turbine speed sensor 1.

AT-05560

25) Remove the turbine speed sensor 1 connector mounting bolt and rotate the sensor by 180°.

5AT-39

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Automatic Transmission Assembly AUTOMATIC TRANSMISSION

CAUTION: Failure to follow this procedure may cause the interference between vehicle body and sensor while removing/installing transmission, and resulting in damage.

33) Remove the nuts connecting the engine mounting and the transmission main mounting bracket.

RH

LH AT-05561

26) Remove the propeller shaft. 27) Remove the select cable. 28) Disconnect the ATF cooler inlet and outlet hose from the ATF cooler inlet and outlet pipe. AT-05499

34) Remove the radiator upper brackets.

AT-05471

29) Remove the front stabilizer bracket. 30) Remove the bolts which secure front ball joint to the housing. 31) Pull out the drive shaft from transmission. 32) Lower the vehicle.

CO-02595

35) Set the ST on the vehicle and hang the engine. CAUTION: • Set the ST so that the chain does not contact the sensor and other parts while hanging the engine.

5AT-40

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Automatic Transmission Assembly AUTOMATIC TRANSMISSION

• Set the arms of ST (ENGINE HANGER) at the locations shown in the figure. ST1 99099AJ000 SPECIAL TOOL ENGINE HANGER ST2 99099AJ010 SPECIAL TOOL CHAIN BALANCER GENERAL TOOL Sling chain GENERAL TOOL Screw shackle ST2

• Lift the radiator up and keep the position with cloth or other material placed under the radiator.

ST1 AT-05501

AT-05581 (A)

ST2

(A)

ST1 AT-05502

(A) Cloth

37) Attach the ST with the front cushion rubber mounting bolts and nuts. AT-05583

36) Lift the radiator by approximately 30 mm and remove the front cushion rubber. NOTE: • The front cushion rubber cannot be removed from the vehicle unless the radiator is lifted due to a small clearance between the radiator and engine.

CAUTION: Do not tighten the nuts on the engine mount excessively, or the engine mounting bracket may be deformed.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) ST 41099AJ010 SPECIAL TOOL

H6

ST AT-05504

38) Remove the ST (ENGINE HANGER). NOTE: Operation is less efficient with the ST (ENGINE HANGER) attached. Remove it temporarily.

5AT-41

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Automatic Transmission Assembly AUTOMATIC TRANSMISSION

39) Remove the transmission main mounting bracket.

44) Remove the rear crossmember from the vehicle.

RH

AT-01377

45) Remove the transmission mounting bolt and nut (lower side).

LH

AT-05500

40) Remove the transmission mounting bolt (upper side).

AT-05591

46) Remove the transmission. 47) Remove the rear crossmember and cushion rubber from the transmission.

B: INSTALLATION 1) Replace the front differential side retainer oil seal. (1) Remove the oil seal by using flat tip screwdriver etc. (2) Using the ST, install the oil seal by lightly tapping with a plastic hammer.

AT-05592

41) Attach the ST (ENGINE HANGER) again. 42) Lift up the vehicle. 43) Set the transmission jack under the transmission.

NOTE: • Use a new oil seal. • Check the identification marks (L, R) during installation not to mix up the oil seal RH and LH. • Apply gear oil to the oil seal lips.

AT-05472

5AT-42

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Automatic Transmission Assembly AUTOMATIC TRANSMISSION

• Be sure to replace the differential side retainer oil seal whenever the front drive shaft is removed from the transmission. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER

CAUTION: Do not apply excessive load or impact to the transmission case.

ST

AT-05616

5) While lifting up the transmission gradually using transmission jack, install the transmission to the engine. 6) Install the engine mounting bolt and nut (lower side).

AT-00029

2) Attach the ST to converter case. ST 498277200 STOPPER SET

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

ST AT-00103

3) Install the rear crossmember and cushion rubber to the transmission. AT-05591

Tightening torque: T1: 35 N·m (3.6 kgf-m, 25.8 ft-lb) T2: 40 N·m (4.1 kgf-m, 29.5 ft-lb)

7) Install the transmission rear crossmember.

Tightening torque: 75 N·m (7.6 kgf-m, 55.3 ft-lb)

T2

T2

T1

AT-05619

4) Tap the transmission hanger in the rear side of transmission with a rubber hammer to bend it until it is in close contact with the transmission case.

AT-01377

8) Remove the transmission jack. 9) Lower the vehicle. 10) Install the engine mounting bolt (upper side).

5AT-43

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Automatic Transmission Assembly AUTOMATIC TRANSMISSION

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

Tightening torque: T1: 25 N·m (2.5 kgf-m, 18.4 ft-lb) T2: 45 N·m (4.6 kgf-m, 33.2 ft-lb)

T2

T1 T1 AT-05592 AT-05537

11) Remove the ST (ENGINE HANGER). 12) Install the transmission main mounting bracket.

Tightening torque: 75 N·m (7.6 kgf-m, 55.3 ft-lb)

RH (A)

(A)

AT-05502

(A) Cloth

(2) Install the radiator upper brackets.

Tightening torque: 12 N·m (1.2 kgf-m, 8.9 ft-lb)

LH

AT-05500

13) Attach the ST (ENGINE HANGER) again. 14) Remove the ST and install the front cushion rubber. (1) Lift the radiator by approximately 30 mm and install the front cushion rubber.

CO-02595

15) Remove the ST from the vehicle. 16) Tighten the nuts connecting the engine mounting and the transmission main mounting bracket.

NOTE: • The front cushion rubber cannot be installed to the vehicle unless the radiator is lifted due to a small clearance between the radiator and engine. • Lift the radiator up and keep the position with cloth or other material placed under the radiator.

5AT-44

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Automatic Transmission Assembly AUTOMATIC TRANSMISSION

Tightening torque: 45 N·m (4.6 kgf-m, 33.2 ft-lb)

21) Set the ST to side retainer. ST 28399SA010 OIL SEAL PROTECTOR

RH

ST AT-00110

22) Install the front drive shaft into the transmission. 23) Connect the ATF cooler inlet and outlet hose to the ATF cooler inlet and outlet pipe.

LH

AT-05499

17) Remove the ST from converter case. 18) Install the torque converter to drive plate. CAUTION: • Be careful not to drop bolts into converter housing. • Be careful not to damage the mounting bolts. (1) Install the bolts which connect the torque converter and drive plate. (2) Install all four bolts by rotating the crank pulley a little at a time. (3) Install the service hole plug.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-05471

24) Insert the ball joint into housing. 25) Install the front stabilizer bracket. 26) Install the propeller shaft. 27) Install the select cable. 28) Rotate the turbine speed sensor 1 by 180° and then restore it to the original position to install. Then, connect the connector.

Tightening torque: 7 N·m (0.7 kgf-m, 5.2 ft-lb)

AT-05467

19) Install the starter. 20) Lift up the vehicle.

AT-05562

29) Install the oil charge pipe. NOTE: Use new gaskets and O-rings.

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Automatic Transmission Assembly AUTOMATIC TRANSMISSION

Tightening torque: 38 N·m (3.9 kgf-m, 28.0 ft-lb)

Tightening torque: 13 N·m (1.3 kgf-m, 9.6 ft-lb)

AT-05468

AT-05558

30) Install the steering shaft universal joint. 31) Install the heat shield cover. 32) Install the front and rear exhaust pipe. 33) Install the under cover. 34) Lower the vehicle. 35) Remove the ST and install the engine hanger rear.

38) Pour ATF from the oil charge pipe. 39) Install the air breather hose. 40) Install the air intake boot. 41) Attach the grille bracket.

Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb) CO-02594

AT-05466

36) Connect the following connectors. (B)

42) Install the air intake duct. 43) Install the collector cover. 44) Connect the ground cable to battery. 45) Perform Clear Memories 2 operation. 46) Perform learning operation. 47) Perform the inspection at the end of repair work, and make sure there is no faulty as below; • Excessive shift shock • Oil leakage from the transmission body, etc. • Occurrence of noise caused by interference etc.

(A) AT-05465

(A) Transmission harness connectors (B) Front oxygen (A/F) sensor

37) Install the ground cable.

5AT-46

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Transmission Mounting System AUTOMATIC TRANSMISSION

10.Transmission Mounting System A: REMOVAL 1. TRANSMISSION REAR CROSSMEMBER & REAR CUSHION RUBBER 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the under cover. 4) Remove the front exhaust pipe. 5) Remove the heat shield cover.

B: INSTALLATION 1. TRANSMISSION REAR CROSSMEMBER & REAR CUSHION RUBBER 1) Install the rear cushion rubber.

Tightening torque: T1: 35 N·m (3.6 kgf-m, 25.8 ft-lb) T2: 40 N·m (4.1 kgf-m, 29.5 ft-lb) T2

T2

T1

AT-05619

2) Install the crossmember.

Tightening torque: 75 N·m (7.6 kgf-m, 55.3 ft-lb) AT-01331

6) Set the transmission jack under transmission. Make sure that the support plate of transmission jack does not touch the oil pan. 7) Remove the transmission rear crossmember.

AT-01377

AT-05681

8) Remove the rear cushion rubber.

3) Remove the transmission jack. 4) Install the heat shield cover. 5) Install the front exhaust pipe. 6) Install the under cover. 7) Lower the vehicle. 8) Connect the ground cable to battery.

C: INSPECTION Repair or replace parts if the results of the inspection below are not satisfied.

1. TRANSMISSION REAR CROSSMEMBER & REAR CUSHION RUBBER Check crossmember for bends or damage. Check that there are no cracks, hardening, or damage on cushion rubbers.

5AT-47

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Extension Case Oil Seal AUTOMATIC TRANSMISSION

11.Extension Case Oil Seal A: INSPECTION Inspect there is no ATF leakage from the joint of transmission and propeller shaft. If a leak is found, replace the oil seal.

B: REPLACEMENT 1) Lift up the vehicle. 2) Clean the transmission exterior. 3) Remove the ATF drain plug to drain ATF. CAUTION: Immediately after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself. 4) Tighten the ATF drain plug.

10) Install the propeller shaft. 11) Install the heat shield cover. 12) Install the rear exhaust pipe. 13) Lower the vehicle. 14) Pour ATF from the oil charge pipe. 15) Check the level and leaks of the ATF.

NOTE: Use a new gasket.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) (B)

(A)

AT-05460

(A) Oil pan (B) ATF drain plug

5) Remove the rear exhaust pipe. 6) Remove the heat shield cover.

AT-01331

7) Remove the propeller shaft. 8) Using the ST, remove the oil seal. ST 398527700 PULLER ASSY 9) Using the ST, install the oil seal. ST 498057300 INSTALLER

5AT-48

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Differential Side Retainer Oil Seal AUTOMATIC TRANSMISSION

12.Differential Side Retainer Oil Seal A: INSPECTION

• Be careful not to spill the differential gear oil on exhaust pipe to prevent it from emitting smoke or fire. If differential gear oil is spilled on the exhaust pipe, wipe it off completely.

Check for leakage of gear oil from differential side retainer oil seal part. If there is an oil leak, replace the oil seal.

(A) (B)

B: REPLACEMENT 1) Disconnect the ground cable from battery. 2) Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. (1) Pull up the two points at the rear (A). (2) Pull up the two points at the front (B) while moving them forward.

AT-05473

(A) Oil pan (B) Differential gear oil drain plug

7) Tighten the differential gear oil drain plug. NOTE: Use a new gasket.

(A)

(A)

(B)

(B) ME-04447

3) Lift up the vehicle. 4) Remove the under cover. 5) Remove the front exhaust pipe. 6) Remove the differential gear oil drain plug using TORX® bit T70, and then drain differential gear oil. CAUTION: • Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to burn yourself.

Tightening torque: 70 N·m (7.1 kgf-m, 51.6 ft-lb) 8) Separate the front drive shaft from the transmission. 9) Remove the differential side retainer oil seal using driver wrapped with vinyl tape etc. 10) Using the ST, install the differential side retainer oil seal by lightly tapping with a plastic hammer. NOTE: • Use a new oil seal. • Apply differential gear oil to the oil seal lips. • Check the identification marks (L, R) during installation not to mix up the oil seal RH and LH. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER ST

AT-00029

11) Install the front drive shaft. 12) Install the front exhaust pipe. 13) Install the under cover.

5AT-49

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Differential Side Retainer Oil Seal AUTOMATIC TRANSMISSION

14) Lower the vehicle. 15) Connect the ground cable to battery. 16) Pour differential gear oil into the level gauge hole. 17) Check the level of differential gear oil. 18) Install the collector cover.

5AT-50

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Inhibitor Switch AUTOMATIC TRANSMISSION

13.Inhibitor Switch A: INSPECTION Inhibitor switch cannot be checked, because the inhibitor switch is installed on control valve assembly. When a malfunction occurs, refer to 5AT (diag) section.

5AT-51

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Front Vehicle Speed Sensor AUTOMATIC TRANSMISSION

14.Front Vehicle Speed Sensor

8) Remove the front vehicle speed sensor securing bolt.

A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Disconnect the rear vehicle speed sensor connector. NOTE: Secure the transmission harness to the transmission body using wire etc.

AT-05593

9) Remove the front vehicle speed sensor through the hole of AT transmission main case.

B: INSTALLATION 1) Install the front vehicle speed sensor.

Tightening torque: 7 N·m (0.7 kgf-m, 5.2 ft-lb) AT-05520

3) Remove the extension case.

AT-05593

2) Connect the front vehicle speed sensor connector. AT-05521

4) Remove the center differential carrier. 5) Lay along the transmission case, and then remove the oil pan. 6) Remove the old gasket on the oil pan and transmission case completely. 7) Disconnect the front vehicle speed sensor connector. AT-04219

3) Apply proper amount of liquid gasket to the entire oil pan mating surface.

AT-04219

5AT-52

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Front Vehicle Speed Sensor AUTOMATIC TRANSMISSION

Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent

AT-03249

4) Install the oil pan by equally tightening the bolts.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb) 5) Install the center differential carrier. 6) Install the extension case. Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-05521

7) Connect the rear vehicle speed sensor connector.

AT-05520

8) Install the transmission assembly to the vehicle.

9) Pour ATF from the oil charge pipe. 10) Check the level and leaks of ATF.

5AT-53

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Rear Vehicle Speed Sensor AUTOMATIC TRANSMISSION

15.Rear Vehicle Speed Sensor

2) Connect the rear vehicle speed sensor connector.

A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Clean the transmission exterior. 5) Remove the bolts which connect the front exhaust pipe and rear exhaust pipe. 6) Remove the bolts holding the heat shield cover, and move the heat shield cover to the rear. 7) Disconnect the rear vehicle speed sensor connector.

AT-05520

3) Install the heat shield cover. 4) Tighten the bolts which connect the front exhaust pipe and rear exhaust pipe.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb) 5) Lower the vehicle.

AT-05520

8) Remove the rear vehicle speed sensor.

AT-04261

B: INSTALLATION 1) Install the rear vehicle speed sensor.

Tightening torque: 7 N·m (0.7 kgf-m, 5.2 ft-lb)

AT-04261

5AT-54

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Turbine Speed Sensor 1 AUTOMATIC TRANSMISSION

16.Turbine Speed Sensor 1 A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the front exhaust pipe. 4) Disconnect the turbine speed sensor 1 connector.

AT-05601

5) Remove the turbine speed sensor 1.

B: INSTALLATION 1) Install the turbine speed sensor 1.

Tightening torque: 7 N·m (0.7 kgf-m, 5.2 ft-lb) 2) Connect the turbine speed sensor 1 connector.

AT-05601

3) Install the front exhaust pipe. 4) Lower the vehicle. 5) Connect the ground cable to battery.

5AT-55

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Control Valve Body AUTOMATIC TRANSMISSION

17.Control Valve Body

NOTE: The control valve body is replaced as an assembly only, because it is a non-disassembly part.

A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Lift up the vehicle. 4) Clean the transmission exterior. 5) Remove the ATF drain plug to drain ATF. CAUTION: Directly after the vehicle has been running or the engine has been long idle running, the ATF is hot. Be careful not to burn yourself. 6) Tighten the ATF drain plug.

AT-04221

B: INSTALLATION

NOTE: Use a new gasket.

1) Check the control valve body for dust and other foreign matter. 2) Install the control valve body to transmission by equally tightening the bolts.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) 7) Remove the oil pan. CAUTION: Be sure to prevent the entering of dust and other foreign matters into oil pan. 8) Remove the magnet.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb) (1)

(1)

(1) (1)

(1) (1)

(1)

(1)

(1) (1)

(2)

(1)

(2)

AT-04222

(1) 30 mm (1.18 in) (2) 40 mm (1.57 in)

AT-01959

9) Clean the magnet. 10) Completely remove the remaining liquid gasket on the transmission case and oil pan. 11) Disconnect the control valve connector and front vehicle speed sensor connector.

3) Connect the control valve connector and front vehicle speed sensor connector. (A)

(A)

(A) (A)

(B)

(B)

AT-04220

(A) Control valve connector (B) Front vehicle speed sensor connector

AT-04220

(A) Control valve connector (B) Front vehicle speed sensor connector

12) Remove the control valve body.

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Control Valve Body AUTOMATIC TRANSMISSION

4) Attach the magnet at the specified position of the oil pan.

AT-01959

5) Apply liquid gasket to the oil pan.

Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent

AT-03249

6) Install the oil pan by equally tightening the bolts.

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb) 7) Lower the vehicle. 8) Connect the ground cable to battery. 9) Pour ATF through the oil charge pipe. 10) Check the ATF level. 11) Perform Clear Memories 2 operation. 12) Perform learning operation. 13) Perform the inspection at the end of repair work, and make sure there is no faulty as below; • Excessive shift shock • Oil leakage from the transmission body, etc. • Occurrence of noise caused by interference etc.

C: INSPECTION Check each parts for holes, damages or other foreign matters.

5AT-57

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Transmission Control Module (TCM) AUTOMATIC TRANSMISSION

18.Transmission Control Module (TCM) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. 3) Disconnect the connector from TCM.

(A)

4) Install the instrument panel lower cover. 5) Perform Clear Memories 2 operation. 6) Perform learning operation.

(B)

AT-04384

(A) Transmission control module (TCM) (B) Steering column

4) Remove the TCM. NOTE: Replace the TCM and bracket as a set.

B: INSTALLATION 1) Install the TCM to the bracket. CAUTION: Do not remove the TCM after installed to the bracket, or the bracket and TCM may be damaged. If installed by mistake, the part must be replaced with a new part. 2) Install the TCM.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

(A)

(B)

AT-04384

(A) Transmission control module (TCM) (B) Steering column

3) Connect the connector to TCM.

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ATF Cooler Pipe and Hose AUTOMATIC TRANSMISSION

19.ATF Cooler Pipe and Hose

• If it is hard to remove the ATF cooler hose, wrap the hose with cloth to prevent from damaging it, and while turning with pliers, pull straight out by hand.

A: REMOVAL 1) Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. (1) Pull up the two points at the rear (A). (2) Pull up the two points at the front (B) while moving them forward.

AT-05474

(A)

(A)

(B)

8) Remove the oil charge pipe. 9) Remove the ATF cooler inlet pipe and outlet pipe from the transmission.

(B) ME-04447

2) Remove the battery. 3) Lift up the vehicle. 4) Remove the under cover. 5) Remove the front exhaust pipe. 6) Disconnect the ATF cooler hose from the radiator.

NOTE: When disconnecting the ATF cooler outlet pipe, be careful not to lose the ball and spring used together with the retaining screw.

NOTE: • Do not use a screwdriver or other pointed tools. • If it is hard to remove the ATF cooler hose, wrap the hose with cloth to prevent from damaging it, and while turning with pliers, pull straight out by hand.

(A) (B) AT-05505

(A) ATF cooler outlet pipe (B) ATF cooler inlet pipe

10) Lower the vehicle.

AT-05510

7) Disconnect the ATF cooler hoses from ATF cooler pipes. NOTE: • Do not use a screwdriver or other pointed tools.

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ATF Cooler Pipe and Hose AUTOMATIC TRANSMISSION

11) Remove the ATF cooler pipe assembly mounting bolt.

B: INSTALLATION 1) Install the ATF cooler pipe to frame. CAUTION: Be careful not to bend the A/C pipe, when installing the ATF cooler pipe.

Tightening torque: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

AT-05638

12) Detach the A/C pipe from clip.

AT-05638

2) Install the A/C pipe to clip. 3) Lift up the vehicle. 4) Install the ATF cooler inlet and outlet pipes with new gaskets. AT-05639

13) Remove the ATF cooler pipe from frame.

NOTE: Use a new bolt for the converter case joint.

Tightening torque: T1: 38 N·m (3.9 kgf-m, 28.0 ft-lb) T2: 40 N·m (4.1 kgf-m, 29.5 ft-lb) T3: 45 N·m (4.6 kgf-m, 33.2 ft-lb) T1

T2

T1 T3 AT-05525

5) Install the oil charge pipe. 6) Connect the ATF cooler hose to the ATF cooler pipe on the transmission side.

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ATF Cooler Pipe and Hose AUTOMATIC TRANSMISSION

NOTE: • Use a new ATF cooler hose. • Install so that the ATF cooler hose is not folded over, excessively bent or twisted. • Insert the ATF cooler hose to the specified position.

C: INSPECTION Repair or replace any faulty ATF cooler hoses, ATF cooler pipes, clamps, and washers found in the inspection below. 1) Check for ATF leaks in joints between the transmission, radiator, ATF cooler pipes, and ATF cooler hoses. 2) Check the clamp for deformation. 3) Lightly bend the ATF cooler hose and check for cracks in the surface or other damages. 4) Pinch the ATF cooler hose with your fingers and check for poor elasticity. 5) Check for peeling, cracks, and deformation at the tip of the ATF cooler hose.

AT-05474

7) Connect the ATF cooler hose to the ATF cooler pipe on the radiator side. NOTE: • Use a new ATF cooler hose. • Install so that the ATF cooler hose is not folded over, excessively bent or twisted. • Insert the ATF cooler hose to the specified position.

AT-05510

8) Install the front exhaust pipe. 9) Install the under cover. 10) Lower the vehicle. 11) Install the battery. 12) Fill ATF. NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, ATF cooler pipes, and ATF cooler hoses. 13) Install the collector cover.

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Air Breather Hose AUTOMATIC TRANSMISSION

20.Air Breather Hose A: REMOVAL 1) Remove the collector cover. NOTE: Follow the steps below when removing the collector cover. (1) Pull up the two points at the rear (A). (2) Pull up the two points at the front (B) while moving them forward.

(A)

(A)

(B)

(B) ME-04447

2) Remove the air intake boot. 3) Disconnect the air breather hose.

AT-05564

B: INSTALLATION 1) Connect the air breather hose.

AT-05564

2) Install the air intake boot. 3) Install the collector cover.

C: INSPECTION Make sure the air breather hose is not cracked or clogged.

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Oil Charge Pipe AUTOMATIC TRANSMISSION

21.Oil Charge Pipe

5) Lower the vehicle. 6) Connect the ground cable to battery.

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the under cover. 4) Remove the front exhaust pipe. 5) Disconnect the connector from turbine speed sensor 1. 6) Remove the oil charge pipe, and then remove the O-ring from flange side.

C: INSPECTION • Make sure the oil charge pipe is not deformed or damaged. • Check that there are no ATF leaks from the Oring.

(A) (B)

AT-05565

(A) ATF level gauge (B) Oil charge pipe

B: INSTALLATION 1) Install the oil charge pipe. NOTE: Use new gaskets and O-rings.

Tightening torque: 38 N·m (3.9 kgf-m, 28.0 ft-lb) (A) (B)

AT-05565

(A) ATF level gauge (B) Oil charge pipe

2) Connect the connector to the turbine speed sensor 1. 3) Install the front exhaust pipe. 4) Install the under cover.

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Torque Converter Assembly AUTOMATIC TRANSMISSION

22.Torque Converter Assembly A: REMOVAL 1) Remove the transmission assembly from vehicle body. 2) Pull out the torque converter and oil pump shaft horizontally.

6) Install the transmission assembly to the vehicle.

C: INSPECTION Make sure the ring gear and protrusion of torque converter end are not deformed or damaged.

NOTE: • Be sure not to scratch the inside of bushing in oil pump shaft. • Be careful that the oil pump shaft may drawn out simultaneously.

AT-00113

3) Remove the oil pump shaft from torque converter as necessary.

B: INSTALLATION 1) When the oil pump shaft is removed, install the shaft to torque converter. NOTE: • Use a new circlip. • Make sure the circlip is firmly inserted. 2) Install the oil pump shaft to torque converter, and then make sure that the clip is secured on groove. 3) Apply ATF to the revolving and sliding surface of the oil pump shaft. 4) Holding the torque converter assembly by hand, lightly rotate it to engage with the oil pump rotor. 5) Check the protruding dimension of the torque converter assembly. Dimension A: 8 mm (0.31 in) or less A

AT-05600

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Drive Plate AUTOMATIC TRANSMISSION

23.Drive Plate A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Use the ST to lock the crankshaft, and remove the drive plate. ST 498497100 CRANKSHAFT STOPPER

ST ME-00136

B: INSTALLATION 1) Temporarily tighten the drive plate. 2) Using the ST, lock the crankshaft. ST 498497100 CRANKSHAFT STOPPER

ST AT-05096

3) Tighten the drive plate mounting bolt. NOTE: Tighten the drive plate mounting bolts gradually. Each bolt should be tightened in a crisscross order.

Tightening torque: 90 N·m (9.2 kgf-m, 66.4 ft-lb) 4) Install the transmission assembly to the vehicle.

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Extension Case AUTOMATIC TRANSMISSION

24.Extension Case

B: INSTALLATION

A: REMOVAL

1) Attach the selected reduction driven gear shim to end surface of reduction driven gear with vaseline. 2) Install the extension case.

1) Remove the transmission assembly. 2) Disconnect the rear vehicle speed sensor connector.

NOTE: Use a new gasket.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

AT-05520

3) Remove the rear vehicle speed sensor. AT-05521

3) Install the rear vehicle speed sensor.

Tightening torque: 7 N·m (0.7 kgf-m, 5.2 ft-lb)

AT-04261

4) Remove the extension case.

AT-04261

4) Connect the rear vehicle speed sensor connector.

AT-05521

AT-05520

5) Install the transmission assembly.

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Extension Case AUTOMATIC TRANSMISSION

C: DISASSEMBLY

D: ASSEMBLY

1) Take out the transfer clutch and rear drive shaft by lightly tapping the end of rear drive shaft.

1) Press-fit the oil seal using the ST and press.

NOTE: Be careful not to damage the oil seal of the extension. 2) Remove the snap ring using the ST and press. ST 18762AA000 COMPRESSOR SPECIAL TOOL

NOTE: Use a new oil seal. ST 498057300 INSTALLER 2) Press-fit the dust cover. 3) Insert the transfer clutch assembly, spring retainer, return spring and clutch spring retainer. (D)

ST (C) (B) (A)

AT-03230 AT-03228

(A) (B) (C) (D)

3) Supply compressed air to remove the clutch piston.

Clutch spring retainer Return spring Spring retainer Transfer clutch piston ASSY

4) Using the ST and compressor, install the snap ring. ST 18762AA000 COMPRESSOR SPECIAL TOOL ST AT-03229

4) Remove the dust cover from extension case. 5) Remove the oil seal from the extension case.

AT-03228

5) Install the transfer clutch. 6) Install the rear drive shaft.

E: INSPECTION • Use compressed air to make sure the extension case routes are not clogged or leaking. • Inspect the extension end play, and adjust it to within the standard value.

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Transfer Clutch AUTOMATIC TRANSMISSION

25.Transfer Clutch A: REMOVAL 1) Remove the transmission assembly from vehicle body. 2) Remove the extension case, and then remove the transfer clutch.

2) Using the ST, measure the depth “A”, which is from mating surface of extension case to ball bearing outer ring contact surface. ST 398643600 GAUGE

A

B: INSTALLATION 1) Select the rear drive shaft shim. 2) Select driven plate No. 3 3) Install the extension case. 4) Install the transmission assembly to the vehicle.

AT-03232

A Measured value

3) Using the ST, measure the height “B” from the AT main case mating surface to ball bearing outer ring contact surface. ST 398643600 GAUGE

C: INSPECTION • Inspect the drive plate facing for wear and damage. • Make sure the snap ring is not worn and the return spring has no permanent distortion, damage, or deformation. • Check that the D-ring is not damaged. • Inspect the extension end play, and adjust it to within the standard value.

B

AT-03233

D: ADJUSTMENT

B Measured value

1. REAR DRIVE SHAFT SHIM SELECTION 1) Insert the rear drive shaft into the reduction drive gear and center differential assembly.

AT-03231

4) Calculation formula: When clearances are 0.05 mm (0.0020 in): T (mm) = A – B + 0.23 [T (in) = A – B + 0.0091] When clearances are 0.25 mm (0.0098 in): T (mm) = A – B + 0.03 [T (in) = A – B + 0.0012] A: Depth from end of extension case to ball bearing outer ring contact surface B: Height from end of AT main case contact surface to the ball bearing outer ring contact surface T: Shim thickness

Standard: 0.05 — 0.25 mm (0.0020 — 0.0098 in) NOTE: Calculation formula for “T” above is applied when measuring with the ST (398643600 GAUGE). When not using the ST, When clearances are 0.05 mm (0.0020 in): T (mm) = (A – α) – ((B – β) – 0.28) – 0.05 [T (in) = (A – α) – ((B – β) – 0.011) – 0.0020]

5AT-68

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Transfer Clutch AUTOMATIC TRANSMISSION

When clearances are 0.25 mm (0.0098 in): T (mm) = (A – α) – ((B – β) – 0.28) – 0.25 [T (in) = (A – α) – ((B – β) – 0.011) – 0.0098] is applied. T: Shim thickness A: Depth from end of extension case to ball bearing outer ring contact surface B: Height from end of AT main case contact surface to the ball bearing outer ring contact surface α: Thickness of collar used when measuring “A” β: Thickness of collar used when measuring “B” 0.28 (0.011): Gasket thickness (Unit mm (in)) Part No. 33281AA040 33281AA050 33281AA060

4) Calculation formula: When clearances are 0.2 mm (0.008 in): T (mm) = A – B + 0.08 [T (in) = A – B + 0.0031] When clearances are 0.6 mm (0.024 in): T (mm) = A – B – 0.32 [T (in) = A – B – 0.0126] T: Thickness of driven plate No. 3 A: Depth from mating surface of the extension case to the transfer clutch piston. B: Height from AT main case mating surface to end of ST

Standard: 0.2 — 0.6 mm (0.008 — 0.024 in)

Adjustment shim Thickness mm (in) 0.2 (0.008) 0.5 (0.020) 0.3 (0.012)

2. SELECTION OF DRIVEN PLATE NO. 3 1) Install the drive plate and driven plate to the center differential carrier. 2) Measure the depth “A” from the mating surface of the extension case to the transfer clutch piston.

A

AT-03234

A Measured value

NOTE: Calculation formula for “T” is applied when measuring using ST (398643600 GAUGE, 398744300 PISTON GUIDE). When not using the ST, When clearances are 0.2 mm (0.008 in): T (mm) = A – (B – α – 0.28) – 0.2 [T (in) = A – (B – α – 0.011) – 0.008] When clearances are 0.6 mm (0.024 in): T (mm) = A – (B – α – 0.28) – 0.6 [T (in) = A – (B – α – 0.011) – 0.024] is applied. T: Thickness of driven plate No. 3 A: Depth from mating surface of the extension case to the transfer clutch piston. B: Height from the AT main case mating surface to the contact face of the tool that was used as the substitute of the ST. α: Thickness of tool used when measuring “B” 0.28 (0.011): Gasket thickness (Unit mm (in)) If it is out of specification, select the driven plate No. 3 to adjust within the specification.

3) Using the ST, measure the height “B” from the AT main case mating surface to end of ST, and then subtract the thickness of ST (PISTON GUIDE) (50 mm (1.97 in)) from measured value. ST 398744300 PISTON GUIDE

B

AT-03235

B Measured value

5AT-69

Driven plate No. 3. Part No. Thickness mm (in) 31589AA041 1.6 (0.063) 31589AA050 2.0 (0.079) 31589AA060 2.4 (0.094) 31589AA070 2.8 (0.110)

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Rear Drive Shaft AUTOMATIC TRANSMISSION

26.Rear Drive Shaft

2) Using a press, remove the front and rear side ball bearings and clutch hub.

A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the rear vehicle speed sensor, and then remove the extension case. 3) Pull out the rear driveshaft from center differential assembly.

(B) (A) (C)

AT-00151

(A) Rear ball bearing (B) Rear drive shaft (C) Clutch hub

D: ASSEMBLY Assemble in the reverse order of disassembly. NOTE: • Use new ball bearings and revolution gear. • Make sure the clutch hub is facing the correct direction.

AT-03231

4) Remove the drive plate and driven plate.

B: INSTALLATION 1) Select shims. 2) Install the drive plate and driven plate. 3) Insert the rear driveshaft into the center differential assembly. 4) Combine the extension case, and then install the rear vehicle speed sensor. 5) Install the transmission assembly to the vehicle.

(B)

(A)

(C)

(D)

(A) (B) (C) (D)

C: DISASSEMBLY 1) Using a press, remove the revolution gear.

AT-00152

Front side Clutch hub Rear side Revolution gear

(A)

E: INSPECTION • Check each parts for holes, damages or other foreign matters. • Inspect the extension end play, and adjust it to within the standard value. AT-00149

(A) Revolution gear

5AT-70

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Reduction Driven Gear AUTOMATIC TRANSMISSION

27.Reduction Driven Gear

C: DISASSEMBLY

A: REMOVAL

1) Remove the ball bearing from reduction driven gear using ST. ST 498077300 REMOVER

1) Remove the transmission assembly from vehicle body. 2) Remove the rear vehicle speed sensor, and separate the extension case from transmission case.

3) Remove the center differential carrier. 4) Set the range select lever to the “P” range. 5) Using ST1, ST2 and ST3, pull out the reduction driven gear. ST1 499737100 PULLER SET ST2 18680AA010 GEAR HOLDER ST3 18766AA000 SUPPORT PULLER

(A)

ST

AT-00157

(A) Ball bearing

2) Remove the ball bearing on the reverse side with the same procedure as step 1). ST 498077300 REMOVER

ST2

(A)

ST

(A) ST3 ST1

ST2 AT-03271

(A) Reduction driven gear AT-01969

B: INSTALLATION 1) Set the range select lever to the “P” range. 2) Use a plastic hammer to install reduction driven gear assembly. 3) Select the reduction gear shims. 4) Join the transmission case and the extension case, and then install the rear vehicle speed sensor. 5) Install the transmission assembly to the vehicle.

(A) Ball bearing

3) Remove the snap ring of the parking gear.

AT-03264

5AT-71

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Reduction Driven Gear AUTOMATIC TRANSMISSION

4) Using the ST, remove the parking gear. ST 18767AA000 REMOVER

4) Install the ball bearing on the reverse side with the same procedure as step 3). ST 18654AA000 INSTALLER ST

ST

AT-03265

AT-03268

D: ASSEMBLY

E: INSPECTION

1) Using the ST, install the parking gear. ST 499755602 PRESS

Check the ball bearing and gear for break or damage.

F: ADJUSTMENT 1) Using the ST, measure the height “A” from the AT main case mating surface to ball bearing outer ring contact surface. ST 499575400 GAUGE

ST

ST AT-03266

2) Install the snap ring. A

AT-03269

A Measured value

AT-03264

3) Install the ball bearing to the reduction driven gear using a press.

2) Using the ST, measure the depth “B”, which is from mating surface of extension case to ball bearing outer ring contact surface. ST 499575400 GAUGE

NOTE: Use a new ball bearing. ST 18654AA000 INSTALLER B ST ST

AT-03270

B Measured value

AT-03267

5AT-72

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Reduction Driven Gear AUTOMATIC TRANSMISSION

3) Calculation formula: Select the ball bearing shim from the table to adjust clearances within 0.05 — 0.25 mm (0.0020 — 0.0098 in). When clearances are 0.05 mm (0.0020 in): T (mm) = B – A + 0.23 [T (in) = B – A + 0.0091] When clearances are 0.25 mm (0.0098 in): T (mm) = B – A + 0.03 [T (in) = B – A + 0.0012] T: Shim clearance A: Height from the mating surface of the AT main case to the ball bearing outer ring end surface B: Depth from mating surface of extension case to ball bearing outer ring contact surface Reduction gear shim Part No. Thickness mm (in) 31288AA030 0.2 (0.008) 31288AA050 0.5 (0.020) 31288AA060 0.3 (0.012)

5AT-73

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Center Differential Carrier AUTOMATIC TRANSMISSION

28.Center Differential Carrier

C: DISASSEMBLY

A: REMOVAL

1) Remove the seal ring.

1) Remove the transmission assembly from the vehicle. 2) Remove the rear vehicle speed sensor, and separate the extension case from transmission case.

3) Extract the rear drive shaft. 4) Pull out the center differential carrier assembly.

(A)

AT-02015

(A) Seal ring

2) Remove the ball bearing using the ST and the press. ST 498077600 REMOVER

AT-01972

5) Pull out the shim(s) from transmission case.

B: INSTALLATION 1) Install the center differential assembly with the shim(s). NOTE: Press-fit it to the bottom of bearing shoulder completely.

AT-00167

3) Remove the snap ring, and pull out the pinion shaft from center differential assembly. (B)

AT-01972

(A)

AT-05551

2) Insert the rear drive shaft. 3) Join the transmission case and the extension case, and then install the rear vehicle speed sensor. 4) Install the transmission assembly to the vehicle.

5AT-74

(A) Snap ring (B) Pinion shaft

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Center Differential Carrier AUTOMATIC TRANSMISSION

4) Remove the pinion gear and washers from center differential assembly. (B)

NOTE: Use a new ball bearing. ST 498077000 REMOVER (A) ST (B)

(A)

AT-05594 AT-00170

(A) Pinion gear (B) Washer

5) Pull out the intermediate shaft and thrust bearing.

D: ASSEMBLY 1) Install the thrust bearing onto intermediate shaft. 2) Insert the intermediate shaft into the center differential assembly. 3) Install the pinion gears and washers. 4) Insert the pinion shaft into the center differential assembly. NOTE: • Insert the pinion shaft with the side with the plug side facing the front side (gear side). • After inserting the pinion shaft, adjust its position so that the cutout portion on the front side is on the inner side. FRONT SIDE (GEAR SIDE)

(A) Plate (B) Center differential carrier

7) Apply vaseline onto the seal ring outer surface and shaft grooves. 8) Install a new seal ring.

E: INSPECTION • Check each parts for holes, damages or other foreign matters. • Inspect the extension end play, and adjust it to within the standard value.

REAR SIDE (CLUTCH SIDE) CUTOUT

PLUG

INSERT DIRECTION

AT-05579

5) Install the snap ring. 6) Using a press, press-fit the ball bearing into the center differential assembly.

5AT-75

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Parking Pawl AUTOMATIC TRANSMISSION

29.Parking Pawl

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb)

A: REMOVAL 1) Remove the transmission assembly from vehicle body. 2) Remove the extension case. 3) Remove the center differential carrier. 4) Remove the front vehicle speed sensor. 5) Remove the parking support actuator.

AT-03236

4) Using the ST, tighten the bolts which tightened in step 3) with specified angle. NOTE: Do not use extension as much as possible.

Tightening angle: 17°±2° ST 18854AA000 ANGLE GAUGE

AT-03236

6) Remove the parking pawl, parking pawl shaft and return spring.

ST

AT-02071 ST

AT-03272

B: INSTALLATION 1) Set the transmission to the N range. 2) Install the parking pawl, parking pawl shaft and return spring.

AT-03272

3) Install the parking support actuator.

5AT-76

AT-02072

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Parking Pawl AUTOMATIC TRANSMISSION

5) Make sure that the return spring is sticking out of the parking pole hole.

B B

B

B

(A)

(B) AT-003370

(A) Parking pawl (B) Return spring

6) Install the front vehicle speed sensor. 7) Install the center differential carrier. 8) Install the extension case. 9) Install the transmission assembly to the vehicle.

C: INSPECTION Make sure that the tab of parking pawl on reduction driven gear is not worn or otherwise damaged.

5AT-77

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Converter Case AUTOMATIC TRANSMISSION

30.Converter Case A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Remove the torque converter assembly. 3) Remove the transmission harness connector from stay. 4) Remove the turbine speed sensor 1. 5) Remove the ATF inlet and outlet pipes. 6) Remove the converter case attachment bolts. 7) Lay along the transmission body, and then remove the oil pan. 8) Remove the three converter case mounting bolts (TORX®). ST 18676AA020 TORX® WRENCH

3) Install the front differential assembly to the case.

4) Install the right and left side retainers. 5) Apply proper amount of liquid gasket to the entire matching surface of converter case.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

AT-01975

6) Install the converter case assembly without damaging bushing and oil seal. NOTE: Use a new bolt for the oil charge pipe and ATF cooler pipe portions

AT-04224

9) Separate the converter case by lightly tapping with plastic hammer. 10) Remove the front differential assembly. 11) Remove the oil seal from converter case.

B: INSTALLATION

Tightening torque: Oil charge pipe and ATF cooler pipe portions 38 N·m (3.9 kgf-m, 28.0 ft-lb) Other than the above 41 N·m (4.2 kgf-m, 30.2 ft-lb) 7) Install the three converter case mounting bolts (TORX®). Tightening torque: 41 N·m (4.2 kgf-m, 30.2 ft-lb) ST 18676AA020 TORX® WRENCH

1) Check the appearance of each component and clean them. 2) Press-fit the oil seal to converter case using ST. NOTE: Use a new oil seal. ST 499587100 OIL SEAL INSTALLER ST AT-04224

8) Apply proper amount of liquid gasket to the entire oil pan mating surface, and then install it.

Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent AT-01979

5AT-78

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Converter Case AUTOMATIC TRANSMISSION

Tightening torque: 5 N·m (0.5 kgf-m, 3.7 ft-lb)

AT-03249

9) Install the transmission harness connector to the stay. 10) Install the ATF cooler pipe. 11) Install the torque converter assembly. 12) Install the transmission assembly to the vehicle.

C: INSPECTION Measure the backlash, and then adjust it to be within specification.

5AT-79

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Oil Pump Cover AUTOMATIC TRANSMISSION

31.Oil Pump Cover

6) Install the transmission assembly to the vehicle.

A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Pull out the torque converter assembly. 3) Remove the transmission harness connector from stay. 4) Remove the ATF inlet and outlet pipes. 5) Separate the converter case and transmission case. 6) Remove the oil pump cover mounting bolt, and then separate the oil pump cover from the AT main case by lightly tapping with plastic hammer.

C: DISASSEMBLY 1. FRONT BRAKE 1) Remove the snap ring.

AT-01980

2) Remove the retaining plate, drive plate and driven plate. 3) Using the ST1, ST2 and ST3, remove the snap ring. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT ST1

AT-01976

B: INSTALLATION

ST2

1) Secure the oil pump cover.

Tightening torque: 41 N·m (4.2 kgf-m, 30.2 ft-lb) ST3 AT-01981

4) Remove the retainer and return spring. 5) Remove the front brake piston using compressed air.

AT-01976

2) Install the converter case assembly to the transmission case assembly. 3) Install the transmission harness connector to the stay. 4) Install the ATF cooler pipe. 5) Install the torque converter assembly.

AT-02349

6) Remove the D-ring from front brake piston.

5AT-80

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Oil Pump Cover AUTOMATIC TRANSMISSION

2. OIL PUMP ST1

1) Take out the oil pump housing. ST2

ST3 AT-01981

5) Install the genuine driven plate instead of retaining plate, and temporarily assemble the drive plate and driven plate. Part No. 31536AA290 Driven plate 6) Install the snap ring.

AT-01982

2) Take out the oil pump body.

D: ASSEMBLY 1. FRONT BRAKE 1) Apply ATF to D-ring, and then install it to the front brake piston. 2) Install the front brake piston to oil pump cover. NOTE: Install by aligning the “ ” mark on front brake piston surface with the oil pump cover rib.

AT-01980

7) Measure the clearance between the retaining plate and snap ring. If the value exceeds the specification, replace the drive plate and driven plate as a set and select the retaining plate so that the value is within the specification.

Front brake clearance specification: 0.7 — 1.1 mm (0.028 — 0.043 in)

AT-01983 AT-02350

3) Install the retainer and return spring. 4) Install the front brake piston assembly using ST1, ST2 and ST3. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT

Front brake retaining plate Part No. Thickness mm (in) 31567AB130 3.4 (0.134) 31567AB140 3.6 (0.142) 31567AB150 3.8 (0.150) 31567AB160 4.0 (0.157)

8) Remove the snap ring, replace the driven plate used in measurement of clearance with the retaining plate, and then reassemble.

5AT-81

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Oil Pump Cover AUTOMATIC TRANSMISSION

2. OIL PUMP 1) Apply ATF to oil pump assembly, and then install it to oil pump housing. 2) Install the O-ring to oil pump cover. 3) Install the oil pump housing to the oil pump cover.

Tip clearance: 0.02 — 0.15 mm (0.0008 — 0.0059 in) (A)

(B) (C)

Tightening torque: 10 N·m (1.0 kgf-m, 7.4 ft-lb)

AT-01977

(A) Thickness gauge (B) Inner rotor (C) Outer rotor

(2) Side clearance Set a depth gauge to oil pump housing, then measure the oil pump housing-to-rotor clearance.

AT-01982

E: INSPECTION 1. FRONT BRAKE Check the following items. • Drive plate facing for wear or damage • Snap ring for wear, return spring for damage, and retainer for damage • Piston for damage • D-ring for damage

Side clearance: 0.02 — 0.045 mm (0.0008 — 0.0018 in) (A)

2. OIL PUMP Check the following items. • Oil pump cover and oil seal for breakage or damage • Oil pump body for scratch or damage 1) Check the seal ring and oil seal for breaks and damage. 2) Check other parts for dents or faults. 3) Oil pump rotor assembly selection (1) Tip clearance Install the inner rotor and outer rotor to oil pump housing. With rotor gears facing each other, measure the crest-to-crest clearance.

(C)

(B) AT-01978

(A) Depth gauge (B) Inner rotor (C) Outer rotor

(3) If the depth and/or side clearance are not within the specification, replace the rotor assembly. Part No. 15008AA130 15008AA140 15008AA150

Oil pump rotor assembly Thickness mm (in) 11.37 — 11.38 (0.4476 — 0.4480) 11.38 — 11.39 (0.4480 — 0.4484) 11.39 — 11.40 (0.4484 — 0.4488)

Check the total end play and adjust it to be within specifications.

5AT-82

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Drive Pinion Shaft Assembly AUTOMATIC TRANSMISSION

32.Drive Pinion Shaft Assembly A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Pull out the torque converter assembly. 3) Remove the transmission harness connector from stay. 4) Remove the ATF inlet and outlet pipes. 5) Separate the converter case and transmission case. 6) Remove the drive pinion shaft mounting bolts, and then remove the drive pinion shaft assembly from oil pump cover.

3) Join the converter case with the transmission case. 4) Install the transmission harness connector to the stay. 5) Install the ATF cooler pipe. 6) Install the torque converter assembly. 7) Install the transmission assembly to the vehicle.

C: DISASSEMBLY 1) Flatten the lock nut tab, and then remove the lock nut while holding the rear spline part of the shaft using ST1 and ST2. Pull out the drive pinion collar. ST1 18667AA010 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER

ST3

ST2 AT-01984 ST1

7) Remove the oil pump cover from AT main case.

B: INSTALLATION

AT-00197

1) Assemble the drive pinion assembly to oil pump cover. NOTE: Be careful not to bend the shim.

2) Remove the O-ring. 3) Separate the roller bearing and outer race from shaft using a press.

Tightening torque: 70 N·m (7.1 kgf-m, 51.6 ft-lb)

(A)

AT-00198

(A) Outer race AT-01984

2) Adjust the tooth contact between drive pinion shaft assembly and the front differential side gear.

5AT-83

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Drive Pinion Shaft Assembly AUTOMATIC TRANSMISSION

4) Separate the front roller bearing from the shaft using a press and the ST. ST 498517000 REPLACER

(A) ST

4) Tighten the new lock nuts using ST1, ST2 and ST3. Calculate the tightening torque using following formula. T2 = L2/(L1 + L2) × T1 T1: 116 N·m (11.8 kgf-m, 85.6 ft-lb) [Required torque setting] T2: Tightening torque L1: ST2 length 0.072 m (2.83 in) L2: Torque wrench length Example: Torque wrench length m (in) 0.4 (15.75) 0.45 (17.72) 0.5 (19.69) 0.55 (21.65)

AT-00199

(A) Front roller bearing

D: ASSEMBLY 1) Measure the dimension “A” of drive pinion shaft. ST 398643600 GAUGE

ST1 ST2 ST3

18667AA010 499787700 499787500

Tightening torque N·m (kgf-m, ft-lb) 98 (10.0, 72.3) 100 (10.2, 73.8) 101 (10.3, 74.5) 102 (10.4, 75.2)

HOLDER WRENCH ADAPTER

NOTE: Attach ST2 to torque wrench as straight as possible. ST3

A

ST2

AT-00200

L1 [m (in)]

A Measured value L2 [m (in)]

2) Using a press, press-fit the new roller bearing into the specified position. NOTE: If excessive force is applied to roller bearing, the roller bearing will not turn easily. (A)

ST1 AT-00202

5) Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If the torque is not within specified range, replace the roller bearing.

Starting torque: 7.6 — 38.1 N (0.775 — 3.88 kgf, 1.7 — 8.6 lbf) (B)

AT-00201

(A) Drive pinion shaft (B) Roller bearing

3) After fitting a new O-ring to the shaft, attach the drive pinion collar to the shaft.

AT-00203

6) Crimp the locknut in 2 locations.

5AT-84

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Drive Pinion Shaft Assembly AUTOMATIC TRANSMISSION

7) Measure the dimension “B” of the drive pinion shaft. ST 398643600 GAUGE

4) Rotate the drive pinion a few times using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 WRENCH

ST1

ST2

B AT-00204 AT-01985

B Measured value

8) Calculate the thickness “t” mm (in) of the drive pinion shim. t = 6.5±0.0625 (0.256±0.0025) – (B – A) 9) Select three or less shims from following table. Part No. 31451AA180 31451AA190 31451AA200 31451AA210 31451AA220 31451AA230

Drive pinion shim Thickness mm (in) 0.150 (0.0059) 0.175 (0.0069) 0.200 (0.0079) 0.225 (0.0089) 0.250 (0.0098) 0.275 (0.0108)

E: INSPECTION

5) Adjust the drive pinion and hypoid driven gear backlash. 6) Apply lead-free red dye evenly on the surface of three to four teeth of the hypoid driven gear. Rotate the drive pinion in the leftward and rightward for several times. Remove the oil pump cover, and check the tooth contact pattern. If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. • Correct tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.

• Make sure that all component parts are free of scratches, holes and other faults. • Adjust the tooth alignment.

(A)

F: ADJUSTMENT 1) Assemble the drive pinion shaft assembly to oil pump cover. 2) Remove the liquid gasket from the mating surface completely. 3) Install the converter case to oil pump cover, and secure them with tightening four bolts evenly. NOTE: Use an old gasket or aluminum washer to prevent damaging the mating surface of the housing.

Tightening torque: 41 N·m (4.2 kgf-m, 30.2 ft-lb)

5AT-85

(B)

MT-01401

(A) Toe side (B) Heel side

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Drive Pinion Shaft Assembly AUTOMATIC TRANSMISSION

• Face contact Check item: Backlash is too large. Contact pattern

• Toe contact (inside contact) Check item: Teeth contact area is too small. Contact pattern

AT-00208

AT-00210

Adjustment: Increase the thickness of the shim according to the procedures for moving the drive pinion closer to the driven gear.

Adjustment: Reduce the thickness of the shim according to the procedure for moving the drive pinion away from the driven gear.

AT-00212

AT-00213

• Flank contact Check item: Backlash is too small. Contact pattern

• Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern

AT-00209

AT-00211

Adjustment: Reduce the thickness of the shim according to the procedure for moving the drive pinion away from the driven gear.

Adjustment: Increase the thickness of the shim according to the procedures for moving the drive pinion closer to the driven gear.

AT-00213

AT-00212

5AT-86

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Drive Pinion Shaft Assembly AUTOMATIC TRANSMISSION

7) If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil seal, screw in the retainer to the marked position. Tighten the lock plate with specified torque.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) (A)

AT-01988

(A) Lock plate

5AT-87

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Front Differential Assembly AUTOMATIC TRANSMISSION

33.Front Differential Assembly

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Pull out the torque converter assembly. 3) Remove the transmission harness connector from stay. 4) Remove the ATF inlet and outlet pipes. 5) Separate the converter case from the transmission case. 6) Remove the differential side retainers using ST. NOTE: Hold the differential case assembly by hand to avoid damaging the differential side retainer mounting hole of the converter case. ST 18630AA010 WRENCH COMPL RETAINER 7) Remove the front differential assembly while being careful not to damage the attachment part of the retainer.

B: INSTALLATION 1) When installing the front differential assembly to the case, be careful not to damage the inside of case (particularly, the differential side retainer mating surface).

(A)

AT-01988

(A) Lock plate

6) Install the converter case to the transmission case. 7) Install the transmission harness connector to the stay. 8) Install the ATF cooler pipe. 9) Install the torque converter assembly. 10) Install the transmission assembly to the vehicle.

C: DISASSEMBLY 1. DIFFERENTIAL CASE ASSEMBLY 1) Remove the taper roller bearing using the ST and the press. ST 498077000 REMOVER

(A)

AT-01987

(A) Front differential ASSY

2) Install the O-ring to left and right side retainers. 3) Using the ST, install the side retainer. ST 18630AA010 WRENCH COMPL RETAINER 4) Adjust the backlash of the front differential. 5) Install the lock plate.

5AT-88

AT-00216

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Front Differential Assembly AUTOMATIC TRANSMISSION

2) Secure the case in a vise, remove the hypoid driven gear tightening bolts, and then separate the hypoid driven gear into case (RH) and case (LH).

2) Remove the oil seal.

(A)

(B) (C) MT-01454

3) Remove the split pin, and then remove the claw. ST 398527700 PULLER ASSY

AT-00217

(A) Hypoid driven gear (B) Differential case (RH) (C) Differential case (LH)

3) Pull out the straight pin and shaft, and then remove the differential bevel gear, washer and differential bevel pinion.

AT-00221

(A) Claw (B) Split pin (C) Pin

(A)

4) Attach two claws to the outer race, and set the ST to side retainer. ST 398527700 PULLER ASSY

AT-00218

(A) Differential case (RH)

2. SIDE RETAINER NOTE: After adjusting the drive pinion backlash and tooth contact, remove and install the oil seal and O-ring. 1) Remove the O-ring. AT-00222

(A) Shaft (B) Claw

AT-00219

5) Restore the removed claws to original position, and install the pin and split pin. 6) Hold the shaft of ST to avoid removing from side retainer, and then remove the bearing outer race.

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Front Differential Assembly AUTOMATIC TRANSMISSION

NOTE: Replace the bearing inner and outer races as a single unit. ST 398527700 PULLER ASSY

Tightening torque: 70 N·m (7.1 kgf-m, 51.6 ft-lb) (A)

(B) (C)

AT-00217

(A) Hypoid driven gear (B) Differential case (RH) (C) Differential case (LH)

AT-00223

(A) Shaft (B) Side retainer

D: ASSEMBLY 1. DIFFERENTIAL CASE ASSEMBLY 1) Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft. 2) Attach the straight pin in the reverse direction.

(A)

5) Measurement of backlash (Selection of washer) (1) Install the SUBARU genuine axle shaft to differential case. Part No. 38415AA070 Axle shaft (2) Measure the gear backlash using ST1 and ST2, and then insert the ST2 through the access window of differential case. NOTE: • Measure the backlash by applying a differential bevel pinion tooth between two differential bevel gear teeth. • When measuring, fix the differential bevel pinion gear in place with a screwdriver covered with waste cloth, or a similar tool.

Standard: 0.13 — 0.18 mm (0.0051 — 0.0071 in) ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE

AT-00218

(A) Differential case (RH)

3) Install the washer and differential bevel gear to differential case (LH). Put the differential case (LH) on the differential case (RH), and assemble the two differential cases. 4) Install the hypoid driven gear and secure by tightening the bolt.

ST1

ST2 AT-00224

(3) If the backlash is not within specification, select a washer from the table below. Washer Part No. 803038021 803038022 803038023

5AT-90

Thickness mm (in) 0.95 (0.037) 1.00 (0.039) 1.05 (0.041)

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Front Differential Assembly AUTOMATIC TRANSMISSION

F: ADJUSTMENT

6) Using the ST, install the taper roller bearing. ST 398487700 DRIFT

1) Using the ST, screw-in the retainer until resistance is felt.

2. SIDE RETAINER NOTE: Install the oil seal and O-ring of side retainer after the adjustment of backlash and tooth contact. 1) Install the bearing outer race to side retainer. 2) Using the ST, install the oil seal. NOTE: • Use a new oil seal. • Apply gear oil to the oil seal lips, and install the oil seal while being careful not to deform the lip. • Check the identification marks (L, R) during installation not to mix up the oil seal RH and LH. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER

NOTE: Screw-in the retainer RH side slightly deeper than the retainer LH. ST 18658AA020 WRENCH COMPL RETAINER 2) Remove the oil pump cover. 3) Remove the liquid gasket from the mating surface completely. 4) Install the oil pump cover to converter case, and secure them with tightening four bolts evenly. NOTE: Use an old gasket or aluminum washer to prevent damaging the mating surface of the housing.

Tightening torque: 41 N·m (4.2 kgf-m, 30.2 ft-lb) 5) Rotate the drive pinion ten times or more using ST1 and ST2. ST1 18667AA010 HOLDER ST2 499787700 WRENCH

ST

AT-00226

ST1

3) Install a new O-ring.

ST2

AT-01985

6) Tighten the LH retainer by rotating the shaft until resistance is felt. Then loosen the retainer RH. Keep tightening the retainer LH, and loosening the retainer RH until the pinion shaft no longer be turned. This is the “zero” state.

AT-00219

E: INSPECTION • Check each component for scratches, damage or other faults. • Measure the backlash, and then adjust it to be within specification.

(A)

AT-01986

(A) Retainer

5AT-91

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Front Differential Assembly AUTOMATIC TRANSMISSION

7) After the “zero” state is established, loosen the retainer LH by 3 notches and secure it with the lock plate. Then loosen the retainer RH and retighten until it stops. Rotate the drive pinion 2 or 3 times. Tighten the retainer RH further 1-3/4 notches. This sets the preload. Finally, secure the retainer with its lock plate.

Backlash: 0.13 — 0.18 mm (0.0051 — 0.0071 in) ST1 499787700 WRENCH ST2 498247001 MAGNET BASE ST3 498247100 DIAL GAUGE ST4 499787500 ADAPTER ST5 498255400 PLATE

(A)

ST1 ST5 ST4

ST2

ST3

AT-01988

(A) Lock plate

NOTE: Turning the retainer by one tooth changes the backlash approx. 0.05 mm (0.0020 in).

AT-05553

10) Adjust the teeth contact of the front differential and drive shaft.

(A)

AT-01989

(A) 0.05 mm (0.0020 in)

8) Install the SUBARU genuine axle shaft to the left and right sides of the front differential. 9) Turn the drive pinion a few times with ST1 and check to see if the backlash is within the specified value, using ST2, ST3, ST4 and ST5. NOTE: Secure the ST1 and stator shaft with the tie-wrap.

5AT-92

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AT Main Case AUTOMATIC TRANSMISSION

34.AT Main Case

12) Remove the middle carrier assembly.

A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Pull out the torque converter assembly. 3) Remove the transmission harness connector from stay. 4) Remove the ATF inlet and outlet pipes. 5) Remove the extension case. 6) Remove the center differential carrier. 7) Remove the reduction driven gear. 8) Separate the converter case from the transmission case. 9) Remove the control valve body. 10) Remove the oil pump cover.

AT-01992

13) Remove the rear carrier assembly.

NOTE: The input clutch pack assembly and front sun gear assembly are also removed together.

AT-01990

11) Remove the needle bearing of the middle carrier assembly.

AT-01993

AT-01991

5AT-93

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AT Main Case AUTOMATIC TRANSMISSION

14) Remove the middle & rear sun gear assembly.

17) Remove the direct clutch assembly.

AT-01997

18) Remove the snap ring of reverse brake.

AT-01994

AT-01998

15) Remove the thrust needle bearing of high & low reverse clutch.

19) Remove the retaining plate. 20) Remove the leaf spring. (A)

B'

B

AT-01995

16) Remove the high & low reverse clutch assembly.

B'

B

(A) AT-03364

AT-01996

(A) Leaf spring

21) Take out the drive plate, driven plate and dish plate.

5AT-94

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AT Main Case AUTOMATIC TRANSMISSION

22) Remove the snap ring of the reverse brake spring retainer. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT

25) Apply compressed air.

ST1 AT-02004

26) Remove the reverse brake piston.

ST2

ST3 AT-02005

27) Remove the thrust bearing and seal ring.

AT-02000

23) Remove the spring retainer. (A) (B) (A)

(A) (B)

AT-02001 (A)

24) Remove the return spring.

AT-04307

(A) Thrust bearing (B) Seal ring AT-02002

B: INSTALLATION 1) Apply ATF to the new seal ring.

5AT-95

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AT Main Case AUTOMATIC TRANSMISSION

2) Install the thrust bearing and new seal ring to the drum support.

5) Install the spring retainer and snap ring. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT

(A) (B) ST1

(A)

(A) (B) (A)

ST2

ST3

AT-04307

(A) Thrust bearing (B) Seal ring

AT-02000

3) Install the reverse brake piston.

6) Install the dish plate.

NOTE: Apply ATF onto the piston sliding surface. ST1 18762AA000 COMPRESSOR SPECIAL TOOL ST2 18765AA000 COMPRESSOR SUPPORT ST3 18763AA000 COMPRESSOR SHAFT 4) Install the return spring.

NOTE: When installing, make sure that the identification mark is facing the rear side of transmission. 7) Install the drive plate and driven plate. NOTE: When the reverse brake is disassembled, use a new drive plate and driven plate set.

AT-02002

5AT-96

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AT Main Case AUTOMATIC TRANSMISSION

8) Install the leaf spring.

(1) Check the amount of drive plate compression “A” described in the wave clutch set of repair parts.

(A)

B'

B

(C)

A

(A) (B) B'

AT-05538

B

A Amount of drive plate compression (A) Drive plate (B) Driven plate (C) Retaining plate

(2) Measure the clearance “B” between the retaining plate and snap ring using a thickness gauge.

(A) AT-03364

(A) Leaf spring

NOTE: • Set shims of the same thickness on both sides so that the retaining plate will not tilt. • Do not push the shim down with force to a point where the waves on the drive plate will become crushed.

9) Install the retaining plate. 10) Install the snap ring of the reverse brake.

B

AT-01998

11) Apply compressed air intermittently to check for operation.

AT-05523

B Clearance between retaining plate and snap ring

(3) Select and install a retaining plate so that the value calculated from the dimension A and B is within the standard. T=A+B T: Piston stroke A: Amount of drive plate compression B: Clearance between retaining plate and snap ring

AT-02004

12) Check the piston stroke.

5AT-97

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AT Main Case AUTOMATIC TRANSMISSION

Initial standard: 2.0 — 2.4 mm (0.08 — 0.09 in) Part No. 31567AB100 31567AB170 31567AB180 31567AB190 31567AB200

16) Install the middle & rear sun gear assembly.

Retaining plate Thickness mm (in) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.8 (0.189) 5.0 (0.197)

13) Install the direct clutch assembly.

AT-01997

AT-01994

14) Install the high & low reverse clutch assembly.

17) Install the rear carrier assembly.

AT-01996

15) Install the thrust needle bearing of the high & low reverse clutch.

AT-01993 AT-01995

5AT-98

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AT Main Case AUTOMATIC TRANSMISSION

23) Install the oil pump cover. (1) Apply ATF to the O-ring of input clutch shaft. (2) Install the oil pump cover to AT main case while supporting the input clutch shaft and oil pump housing with your hand.

18) Install the middle carrier assembly.

AT-01990

(3) Make sure the rear end of drive pinion shaft is engaged to the spline of reduction driven gear.

AT-01992

19) Install the thrust needle bearing of middle carrier assembly.

(A)

AT-02092

(A) Drive pinion shaft

(4) Protect the input clutch shaft with a cloth, and rotate to engage the spline of the input clutch and rear carrier using pliers. AT-01991

20) Measure the total end play, and select the bearing. 21) Install the input clutch pack assembly to oil pump cover.

NOTE: Work with pressing the oil pump cover.

(B)

(A)

AT-02046

(A) Cloth

(A)

(5) Combine the oil pump cover with transmission main case.

AT-02006

(A) Input clutch pack ASSY (B) Front sun gear ASSY

22) Turn the transmission sideways.

5AT-99

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AT Main Case AUTOMATIC TRANSMISSION

C: DISASSEMBLY

Tightening torque: 41 N·m (4.2 kgf-m, 30.2 ft-lb)

1. INPUT CLUTCH PACK ASSEMBLY 1) Remove the front sun gear.

AT-01976

24) Install the center differential carrier. 25) Install the reduction driven gear. 26) Install the extension case. 27) Install the control valve body. 28) Install the converter case assembly to the transmission case assembly. 29) Install the ATF cooler pipe. 30) Install the torque converter assembly. 31) Install the transmission assembly to the vehicle. 32) Perform Clear Memories 2 operation. 33) Perform learning operation. 34) Perform the inspection at the end of repair work, and make sure there is no faulty as below; • Excessive shift shock • Oil leakage from the transmission body, etc. • Occurrence of noise caused by interference etc.

AT-02007

2) Remove the thrust bearing. 3) Remove the snap ring, and then remove the front carrier.

AT-02008

4) Remove the input clutch assembly from rear internal gear.

5AT-100

AT-02009

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AT Main Case AUTOMATIC TRANSMISSION

D: ASSEMBLY

2. INPUT CLUTCH

1. INPUT CLUTCH PACK ASSEMBLY

• Check the clearance of the input clutch. Measure the clearance “L” between snap ring and retaining plate using a thickness gauge. If it is out of specification, replace the entire input clutch assembly. • Check for damage on the drive plate, driven plate and snap ring, and replace the entire input clutch assembly if damaged.

1) Assemble the input clutch assembly to rear internal gear.

Standard: 0.7 — 1.1 mm (0.028 — 0.043 in) L

AT-02009

2) Install the front carrier, and then install the snap ring.

AT-03259

3. HIGH & LOW REVERSE CLUTCH ASSEMBLY • Check the clearance of the high & low reverse clutch. Measure the clearance “L” between snap ring and retaining plate using a thickness gauge. If it is out of specification, replace the entire high & low reverse clutch assembly. • Check for damage on the drive plate, driven plate and snap ring, and replace the entire high & low reverse clutch assembly if damaged.

AT-02008

3) Install the thrust bearing. 4) Install the front sun gear.

Standard: 1.8 — 2.2 mm (0.071 — 0.087 in) L

AT-02007

E: INSPECTION 1. FRONT, MIDDLE & REAR PLANETARY CARRIER ASSEMBLY Check the following items. • Visually inspect the tooth surface of planetary gear, and replace with new part if damaged, broken or excessively worn. • Inspect the planetary carrier body for damage or breakage.

AT-02010

4. DIRECT CLUTCH ASSEMBLY • Check the clearance of direct clutch. Measure the clearance “L” between snap ring and retaining plate using a thickness gauge. If it is out of specification, replace the entire direct clutch assembly. • Check for damage on the drive plate, driven plate and snap ring, and replace the entire direct clutch assembly if damaged.

5AT-101

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AT Main Case AUTOMATIC TRANSMISSION

Standard: 0.6 — 1.0 mm (0.024 — 0.039 in)

3) Calculate the measured value from step 1) and 2), and then set the calculated value as “C”. Calculation formula: C = A – B 4) Using the ST, measure the depth “D” from the AT main case mating surface to thrust bearing transferring surface of front sun gear. ST 499575400 GAUGE

L

AT-02011 D

5. REVERSE BRAKE Check the following items. • Snap ring for wear, return spring for breakage, and spring retainer for deformation • Lip seal and D-ring for damage • Piston operation • Piston stroke

F: ADJUSTMENT 1) Using the ST, measure the height “A” from the AT main case mating surface to convex surface of oil pump cover. ST 499575400 GAUGE ST

A

AT-02012

A Measured value

2) Using the ST, measure the depth “B” from the convex surface of oil pump cover to thrust bearing transferring surface. ST 499575400 GAUGE

B

ST

AT-02014

D Measured value

5) Set the value as “E” which subtract the thickness of ST (499575400 GAUGE) from the measured value on step 4). Calculation: E (mm) = D – 15 [E (in) = D – 0.59] 6) Calculation formula: Select one thrust bearing from the table to adjust clearance within 0.25 — 0.55 mm (0.0098 — 0.0217 in). When clearances are 0.25 mm (0.0098 in): T (mm) = E – C + 0.03 [T (in) = E – C + 0.0012] When clearances are 0.55 mm (0.0217 in): T (mm) = E – C + 0.27 [T (in) = E – C + 0.0106] T: Thrust bearing thickness C: Distance from oil pump cover mating surface to rear end of oil pump cover E: Depth from mating surface of AT main case to bearing surface of front sun gear NOTE: Calculation formula for “T” above is applied when measuring with the ST (499575400 GAUGE). In the calculation without using ST, substitute the thickness of collar used to calculate the value “E” on step 5). Part No. 806548020 606548030 806548040 806548050

ST

AT-02013

806548060 806548070

B Measured value

5AT-102

Thrust bearing Thickness mm (in) 3.2 (0.126) 3.4 (0.134) 3.6 (0.142) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165)

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Transmission Control Device AUTOMATIC TRANSMISSION

35.Transmission Control Device

9) Remove the detent spring.

A: REMOVAL 1) Remove the transmission assembly from the vehicle. 2) Pull out the torque converter assembly. 3) Lift up the lever on the rear side of transmission harness connector, and then disconnect it from the stay. 4) Wrap vinyl tape around the nipple attached to the air breather hose. 5) Remove the transmission hanger COMPL. 6) Remove the control valve body assembly. 7) Pull out the straight pin of manual plate.

AT-00307

B: INSTALLATION 1) Install the detent spring to the transmission case.

Tightening torque: 7 N·m (0.7 kgf-m, 5.2 ft-lb)

AT-00305

8) Remove the bolts securing range select lever, and then remove the select lever, manual plate and parking rod. NOTE: Be careful not to damage the lips of press-fitted oil seal in the case.

AT-00307

2) Insert the range select lever, and tighten the bolts.

Tightening torque: 6 N·m (0.6 kgf-m, 4.4 ft-lb)

AT-00308 AT-00306

(A) (B) (C) (D)

Bolt Range select lever Manual plate Parking rod

5AT-103

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Transmission Control Device AUTOMATIC TRANSMISSION

3) Insert the manual plate and parking rod.

AT-00306

(A) (B) (C) (D)

Bolt Range select lever Manual plate Parking rod

4) Insert the straight pin to the manual plate.

AT-00305

5) Install the oil pan and the control valve body assembly. 6) Install the transmission hanger COMPL.

Tightening torque: 41 N·m (4.2 kgf-m, 30.2 ft-lb) 7) Insert the transmission connector to the stay. 8) Install the air breather hose. 9) Install the torque converter assembly. 10) Install the transmission assembly to the vehicle.

C: INSPECTION Make sure the manual lever and detent spring are not worn or otherwise damaged.

5AT-104

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION

36.Diagnostics with Phenomenon A: INSPECTION Symptoms

Faulty parts

Engine does not start when the select lever is in “N” and “P” range. Engine starts when the select lever is in a range other than “N” or “P” range. The vehicle is not switched to parting mode when the select lever is in “P” range. Parking mode is not canceled even if the select lever is shifted from “P” range to another range. Excessive shock when the select lever is shifted from “N” range to “D” range or from “N” range to “R” range.

Engine stalls when the select lever is shifted from “N” range to “D” range or from “N” range to “R” range.

Excessive shift shock while driving with the select lever in “D” range.

Excessive shock at lock-up or lock-up does not occur when the select lever is in “D” range.

Cannot drive in all ranges.

The vehicle can run when the select lever is in “P” and “N” range.

Excessively poor acceleration when the select lever is in “D” range.

Noise emitted from transmission

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Select cable Inhibitor switch TCM Select cable Inhibitor switch TCM Inhibitor switch Select cable Parking mechanism Inhibitor switch Select cable Parking mechanism ATF Turbine speed sensor Line pressure solenoid Line pressure circuit ATF Turbine speed sensor Line pressure circuit Lock-up solenoid Lock-up pressure circuit Engine speed signal TCM ATF Vehicle speed sensor Turbine speed sensor Line pressure circuit Engine speed signal TCM Vehicle speed sensor Turbine speed sensor Line pressure circuit Lock-up solenoid Lock-up pressure circuit Engine speed signal TCM ATF Select cable Inhibitor switch Line pressure solenoid Line pressure circuit Engine speed signal TCM Gear and clutch Inhibitor switch Select cable ATF Line pressure solenoid Line pressure circuit Vehicle speed sensor Engine speed signal TCM Gear and clutch ATF Gear, clutch and bearing Control valve

5AT-105

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION

5AT-106

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AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5AT(diag) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Page Basic Diagnostic Procedure .......................................................................2 Check List for Interview ..............................................................................4 General Description ...................................................................................5 Electrical Component Location ..................................................................7 Transmission Control Module (TCM) I/O Signal ......................................13 Subaru Select Monitor ..............................................................................17 Read Current Data ...................................................................................18 Read Diagnostic Trouble Code (DTC) .....................................................20 Clear Memory Mode .................................................................................21 Inspection Mode .......................................................................................22 Learning Control .......................................................................................23 AT OIL TEMP Warning Light Display .......................................................25 AWD Warning Light Display .....................................................................28 Diagnostic Procedure for Subaru Select Monitor Communication ...........30 List of Diagnostic Trouble Code (DTC) ....................................................33 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................36 Diagnostic Procedure without Diagnostic Trouble Code (DTC) ...............97 Diagnostics with Phenomenon .................................................................98

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Basic Diagnostic Procedure AUTOMATIC TRANSMISSION (DIAGNOSTICS)

1. Basic Diagnostic Procedure A: PROCEDURE 1

2

3

4

5

6

Step CHECK PRE-INSPECTION. 1) Ask the customer when and how the trouble occurred using the interview check list. 2) Check the following items which may be affecting the AT trouble. • General inspection • Oil leakage • Stall speed test • Line pressure test • Transfer clutch pressure test • Time lag test • Road test • Inhibitor switch CHECK AT OIL TEMP LIGHT. Turn the ignition switch to ON and wait for at least 2 seconds. CHECK AT OIL TEMP LIGHT. Start the engine and wait for two seconds or more. CHECK DTC. Read the DTC. NOTE: If the communication function of Subaru Select Monitor cannot be executed normally, check communication circuit. CHECK INFORMATION STORED IN FREEZE FRAME DATA. Using the Subaru Select Monitor, check the freeze frame data. PERFORM GENERAL DIAGNOSTICS. 1) Inspect using “Diagnostic Procedure without Diagnostic Trouble Code (DTC)”. 2) Perform the Clear Memory Mode. 3) Perform the Inspection Mode. 4) Read the DTC.

Check Yes Is the item that is thought to Go to step 2. influence the AT problem working properly?

No Repair or replace the items which may be affecting the AT trouble.

Does the AT OIL TEMP light illuminate?

Go to step 3.

Check the AT OIL TEMP light.

Does the AT OIL TEMP light blink?

Go to step 4.

Go to step 6.

Is DTC displayed on Subaru Select Monitor?

Record all DTC. Go to step 5.

Go to step 6. NOTE: When the AT OIL TEMP light blinks, check if the learning has completed.

Are freeze frame data recorded?

Record the freeze Go to step 7. frame data. Go to step 7.

Is DTC displayed on Subaru Select Monitor?

Go to step 7.

5AT(diag)-2

Finish the diagnosis.

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Basic Diagnostic Procedure AUTOMATIC TRANSMISSION (DIAGNOSTICS)

7

Step Check PERFORM DIAGNOSIS. Is DTC displayed on Subaru 1) Inspect using “Diagnostic Procedure with Select Monitor? Diagnostic Trouble Code (DTC)”. NOTE: For DTC table, refer to “List of Diagnostic Trouble Code (DTC)”. 2) Repair the trouble cause. 3) Perform the Clear Memory Mode. 4) Perform the Inspection Mode. 5) Read the DTC.

5AT(diag)-3

Yes No Inspect again Finish the diagnousing Diagnostic sis. Procedure with Diagnostic Trouble Code (DTC).

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Check List for Interview AUTOMATIC TRANSMISSION (DIAGNOSTICS)

2. Check List for Interview A: CHECK Check the following items when a problem has occurred. NOTE: Use copies of this page for interviewing customers. Customer’s name Date of purchase Date of repair Transmission model Odometer reading Symptoms

Transmission

km (miles)

( Frequency Weather ( Place ( Ambient air temperature Vehicle speed

V.I.N.

No up-shift No down-shift No kick down Vehicle does not move ( Any position Particular position) Lock-up malfunction Noise or vibration Shift shock or slip Select lever does not move Others ) Continuous Intermittent ( times a day) Fine Cloudy Rainy Snowy Others ) Highland Suburbs Inner city Uphill Rough road Others ) Hot Warm Cool Cold km/h (MPH)

AT OIL TEMP light Select lever position Driving condition

Blinks continuously P R N Not affected At racing While decelerating

Manual mode

ON

D

Does not blink Manual mode At starting While idling When accelerating While cruising While turning ( RH/ LH)

OFF

5AT(diag)-4

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General Description AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3. ATF LEVEL

A: CAUTION

Make sure that ATF level is the specified amount.

1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG” The airbag system wiring harness is routed near the TCM.

(B)

L F COLD L

(B) (C)

AT-04217

(A) Oil level gauge (B) Upper level (C) Lower level

2. MEASUREMENT

B: INSPECTION

(A)

(C)

CAUTION: • All the airbag system wiring harnesses and connectors are colored yellow. Do not use an electric test equipment to check these circuits. • Be careful not to damage the airbag system wiring harness when performing diagnostics or servicing the TCM. When measuring the voltage and resistance of the ECM, TCM or each sensor, use a tapered pin with a diameter of less than 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert a pin of more than 0.65 mm (0.026 in) diameter.

F HOT

3. General Description

4. FRONT DIFFERENTIAL OIL LEVEL Make sure the front differential oil level is the specified amount.

1. BATTERY Measure the battery voltage and specific gravity of the electrolyte. F

Standard voltage: 12 V or more

(A) (B) L

Specific gravity: 1.260 or more

2. TRANSMISSION GROUND

AT-00017

Make sure that the ground terminal bolt is tightened securely.

Tightening torque: 7 N·m (0.7 kgf-m, 5.2 ft-lb)

(A) Upper level (B) Lower level

5. OPERATION OF SHIFT SELECT LEVER Make sure there is no noise, dragging or contact pattern in each select lever range. WARNING: Stop the engine while checking operation of the select lever.

(A)

AT-05682

(A) Ground bolt

5AT(diag)-5

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General Description AUTOMATIC TRANSMISSION (DIAGNOSTICS)

C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 1B022XU0

DESCRIPTION SUBARU SELECT MONITOR III KIT

REMARKS Used for troubleshooting the electrical system.

ST1B022XU0

2. GENERAL TOOL TOOL NAME Circuit tester Oscilloscope

REMARKS Used for measuring resistance, voltage and current. Used for measuring the sensor.

5AT(diag)-6

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Electrical Component Location AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4. Electrical Component Location A: LOCATION 1. CONTROL MODULE (1)

(3)

(4)

(5) (2),(6) AT-05571

(1)

Engine control module (ECM)

(3)

(2)

AT OIL TEMP light

(4)

Transmission control module (TCM) Data link connector

5AT(diag)-7

(5)

Body integrated unit

(6)

AWD light

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Electrical Component Location AUTOMATIC TRANSMISSION (DIAGNOSTICS)

(1)

AT OIL TEMP

(2) EN-07715

AT-05106

(3)

(4) AT-02053

EN-07717

(5)

AWD

(6) AT-04405

5AT(diag)-8

AT-05395

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Electrical Component Location AUTOMATIC TRANSMISSION (DIAGNOSTICS)

2. SENSOR (6)

(3),(5),(7)

(1)

(2)

(4) AT-05683

(1) (2) (3)

Accelerator pedal position sensor Front vehicle speed sensor Inhibitor switch

(4) (5)

Rear vehicle speed sensor Turbine speed sensor 1

5AT(diag)-9

(6) (7)

ATF temperature sensor Turbine speed sensor 2

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Electrical Component Location AUTOMATIC TRANSMISSION (DIAGNOSTICS)

(2) (1)

AT-00375

AT-03281

(5)

(4)

(3) AT-04264

AT-03282

(7) (6)

AT-04265

5AT(diag)-10

AT-04266

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Electrical Component Location AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3. SOLENOID (3)

(5)

(6)

(4) (1)

(7)

(8)

(2) AT-04871

(1) (2) (3)

High & low reverse clutch solenoid Direct clutch solenoid Front brake solenoid

(4) (5) (6)

Input clutch solenoid Line pressure solenoid Lock-up solenoid

5AT(diag)-11

(7) (8)

Transfer solenoid Forward brake solenoid

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Electrical Component Location AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4. OIL PRESSURE SWITCH (2)

(3)

(1)

(4)

(5) AT-04872

(1)

Front brake oil pressure switch

(3)

(2)

Input clutch oil pressure switch

(4)

High & low reverse clutch oil pressure switch Direct clutch oil pressure switch

5AT(diag)-12

(5)

Forward brake oil pressure switch

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Transmission Control Module (TCM) I/O Signal AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5. Transmission Control Module (TCM) I/O Signal A: ELECTRICAL SPECIFICATION

TO

TO

B 54

7 6 5 4 3 2 1 19 18 17 16 15 14 13 12 11 10 9 8 27 26 25 24 23 22 21 20 35 34 33 32 31 30 29 28

6 16 15 27 26 35 34

B 55

5 4 3 2 1 14 13 12 11 10 9 8 7 25 24 23 22 21 20 19 18 17 33 32 31 30 29 28

AT-04576

NOTE: Measure after warming up. Item

P/L solenoid output I/C oil pressure switch input Power GND CAN communication line (+) CAN communication line (–)

Connector No.

Terminal No.

B55

6

B55

Engine ON, “P” range, accelerator OFF, brake ON

3.5 — 7.5 V

While driving at 1st — 3rd of manual mode

6 V or more

While driving at 4th or 5th of manual mode

Less than 1.5 V

Always

Approx. 0 V

12

B54

21







B54

20







B55

Backup power supply

B54

H & LR/C solenoid output

Measured value

B55

ATF temperature sensor 1 input

I/C solenoid output

20

Measuring condition

Resistance between terminal and chassis ground 3 — 9 Ω (ATF temperature 20°C (68°F))

B55

B55

17

24

3

5

Ignition switch ON ATF temperature 20°C (68°F) Ignition switch ON ATF temperature 80°C (176°F) Ignition switch ON Ignition switch OFF

2.5 — 7.0 kΩ

1 — 2.2 V

0.3 — 0.8 kΩ

While driving at 1st — 3rd of manual mode

5 V or more

While driving at 4th or 5th of manual mode

Less than 1.5 V

While driving at 2nd of manual mode

5 V or more

While driving at 1st and Less than 1.5 V 3rd — 5th of manual mode

5AT(diag)-13

Driving frequency 300 Hz



3.5 — 4.3 V

8 V or more

Remarks

Measure the resistance with TCM by itself and the connector disconnected.

— 3 — 9 Ω (ATF temperature 20°C (68°F))

Driving frequency 300 Hz

3 — 9 Ω (ATF temperature 20°C (68°F))

Driving frequency 300 Hz

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Transmission Control Module (TCM) I/O Signal AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Connector No.

Terminal No.

Power GND Analog GND

B55 B55

13 18

Fr/B solenoid output

B55

4

L/U solenoid output

B55

Item

D/C solenoid output

D/C oil pressure switch input

B55

B55

7

1

22

Data link signal (Subaru Select Monitor communication line)

B54

8

Sensor GND (analog)

B55

16

H&LR/C oil pressure switch input

B55

Fwd/B solenoid output

B55

Fwd/B oil pressure switch input

Front vehicle speed sensor input

B55

B55

Inhibitor switch 1 input

B55

Inhibitor switch 2 input

B55

Ignition power supply

B55

14

19

21

24

8

9

27

Measuring condition Always Always While driving at other than 4th of manual mode While driving at 4th of manual mode When lock-up

Measured value Approx. 0 V Approx. 0 V 5 V or more Less than 1.5 V 3 V or more

When not lock-up

Less than 1 V

While driving at 1st or 5th of manual mode

5 V or more

While driving at 2nd-4th of manual mode

Less than 1.5 V

While driving at 1st or 5th of manual mode While driving at 2nd-4th of manual mode

3 — 9 Ω (ATF temperature 20°C (68°F))

Driving frequency 300 Hz

3 — 9 Ω (ATF temperature 20°C (68°F))

Driving frequency 300 Hz

3 — 9 Ω (ATF temperature 20°C (68°F))

Driving frequency 300 Hz

Less than 1.5 V 8 V or more

Ignition switch OFF

Less than 1 V

Always

Approx. 0 V

While driving at 2nd of manual mode

6 V or more





— Less than 1.5 V 5 V or more

While driving at 3rd — 5th of manual mode

Less than 1.5 V

While driving at 1st or 2nd of manual mode

Less than 1.5 V

While driving at 3rd — 5th 6 V or more of manual mode While driving at 2nd and Approx. 500 — 20 km/h (12 MPH) of man700 rpm ual mode While driving at 4th and 80 km/h (50 MPH) of manual mode

Approx. 2,000 — 2,500 rpm

Ignition switch ON, “P” range

Less than 0.5 V

Ignition switch ON, “N” range Ignition switch ON, “P” range

Remarks

6 V or more

Ignition switch ON

While driving at 3rd — 5th of manual mode While driving at 1st or 2nd of manual mode

Resistance between terminal and chassis ground — —

Driving frequency 300 Hz

Use the Subaru Select Monitor. — Use the Subaru Select Monitor.

— 5 V or more 5 V or more —

Ignition switch ON, “D” range

Less than 0.5 V

Ignition switch ON Ignition switch OFF

8 V or more Less than 1 V

5AT(diag)-14



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Transmission Control Module (TCM) I/O Signal AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Item

Rear vehicle speed sensor input

Fr/B oil pressure switch input

Turbine speed sensor 1 input

Connector No.

B55

B55

B55

Terminal No.

23

15

26

Inhibitor switch 3 input

B55

Control GND 1

B54

23

Control GND 2

B54

22

Inhibitor switch 4 input

Back-up light relay output

AWD solenoid output

Turbine speed sensor 2 input

PN signal output

B55

B54

B55

B55

B54

10

11

13

2

25

11

Measuring condition

Measured value

While driving at 2nd and Approx. 500 — 20 km/h (12 MPH) of man700 rpm ual mode While driving at 4th and 80 km/h (50 MPH) of manual mode

Approx. 2,000 — 2,500 rpm

While driving at other than 4th of manual mode

Less than 1.5 V

While driving at 4th of manual mode

6 V or more

2nd gear of manual mode, turbine speed sensor is 2,000 rpm (Read from Subaru Select Monitor)

Approx. 0 rpm

4th of manual mode, turbine speed sensor is 2,000 rpm (Read from Subaru Select Monitor) Ignition switch ON, “R” range Ignition switch ON, “D” range Ignition switch ON Ignition switch OFF

— Use the Subaru Select Monitor.

Use the Subaru Select Monitor.

Approx. 1,900 — 2,100 rpm

Use the Subaru Select Monitor.

5 V or more — Less than 0.5 V Approx. 0 V

Ignition switch ON, “P” range

Less than 0.5 V

Ignition switch ON, “D” range

5 V or more

Ignition switch ON, “R” range

Less than 1 V

Ignition switch ON, other than “R” range

8 V or more

Ignition switch ON, Other than “P” range or “N” range Ignition switch ON, “P” range or “N” range

Use the Subaru Select Monitor.



Approx. 0 V

4th of manual mode, turbine speed sensor is 2,000 rpm (Read from Subaru Select Monitor)

Remarks



Ignition switch ON Ignition switch OFF

Engine ON, “P” range or “N” range, accelerator OFF Engine ON, “D” range, accelerator OFF, brake ON 2nd gear of manual mode, turbine speed sensor is 2,000 rpm (Read from Subaru Select Monitor)

Resistance between terminal and chassis ground



Less than 1 V

2 V or more

90 — 110 Ω (ATF temperature 25°C (77°F))

3 — 9 Ω (ATF temperature 20°C (68°F))

Driving frequency 300 Hz

Approx. 1,200 — 1,500 rpm



Use the Subaru Select Monitor.

Approx. 1,900 — 2,100 rpm



Use the Subaru Select Monitor.

8 V or more



Less than 1 V



5AT(diag)-15

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Transmission Control Module (TCM) I/O Signal AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Connector No.

Terminal No.

Ignition power supply 1

B54

26

Ignition switch ON Ignition switch OFF

8 V or more Less than 1 V

Resistance between terminal and chassis ground — —

Ignition power supply 2

B54

19

Ignition switch ON Ignition switch OFF

8 V or more Less than 1 V

— —

Ignition power supply 3

B54

18

Ignition switch ON Ignition switch OFF

8 V or more Less than 1 V

— —

Ignition power supply 4

B54

25

Ignition switch ON Ignition switch OFF

8 V or more Less than 1 V

— —

Ignition switch ON, Paddle shift DOWN switch ON

Less than 1 V



Ignition switch ON, Paddle shift DOWN switch OFF

8 V or more



Ignition switch ON, Paddle shift UP switch ON

Less than 1 V



Ignition switch ON, Paddle shift UP switch OFF

8 V or more



Ignition switch ON, Manual mode switch ON

Less than 1 V



Ignition switch ON, Manual mode switch OFF

8 V or more



Item

Paddle shift DOWN switch

Paddle shift UP switch

Manual mode switch

B54

B54

B54

4

5

6

Measuring condition

Measured value

5AT(diag)-16

Remarks

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Subaru Select Monitor AUTOMATIC TRANSMISSION (DIAGNOSTICS)

6. Subaru Select Monitor A: OPERATION For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

5AT(diag)-17

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Read Current Data AUTOMATIC TRANSMISSION (DIAGNOSTICS)

7. Read Current Data A: OPERATION For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. • The support data list is as follows. Item Engine speed signal Battery voltage Accelerator position sensor Front vehicle speed sensor signal Gear position Turbine speed sensor signal Rear vehicle speed sensor signal ATF temperature sensor signal Turbine speed sensor 1 signal Turbine speed sensor 2 signal High & low reverse clutch solenoid set current Direct clutch solenoid set current Front brake solenoid set current Input clutch solenoid set current Line pressure solenoid set current Lock-up solenoid set current Transfer solenoid set current High & low reverse clutch solenoid pressure Direct clutch solenoid pressure Front brake solenoid pressure Input clutch solenoid pressure Line pressure solenoid pressure Lock-up solenoid pressure Transfer solenoid pressure

Display Engine Speed Battery Voltage Accel. Opening Angle Front Wheel Speed Gear Position Turbine Revolution Speed Rear Wheel Speed ATF Temp. AT Turbine Speed 1 AT Turbine Speed 2 H&LR/C Solenoid Current D/C Solenoid Current F/B Solenoid Current I/C Solenoid Current P/L Solenoid Current L/U Solenoid Current AWD Sol. Current H&LR/C Solenoid Pressure D/C Solenoid Pressure F/B Solenoid Pressure I/C Solenoid Pressure P/L Solenoid Pressure L/U Solenoid Pressure AWD Solenoid Pressure

Forward brake set current Forward brake solenoid target hydraulic pressure Ignition switch Manual mode signal Cruise control set signal Down shift signal Stop light switch signal Up shift signal Drive range signal Reverse range signal Diagnosis light output signal ATF temperature light signal Parking range signal P/N range output signal Neutral range signal Inhibitor switch 1 input signal Inhibitor switch 2 input signal Inhibitor switch 3 input signal Inhibitor switch 4 input signal Back-up light relay output signal High & low reverse clutch fluid pressure switch input signal

Fwd/B solenoid current Fwd/B solenoid target pressure Ignition Switch Tiptronic Mode Switch Cruise Control Signal Down Switch Stop Light Switch Up Switch D Range Signal R Range Signal Diagnosis Lamp ATF Temperature Lamp P Range P/N Signal N Range Inhibitor SW 1 Inhibitor SW 2 Inhibitor SW 3 Inhibitor SW 4 Back Lamp Relay H&LR/C Fluid Pressure

5AT(diag)-18

Unit of measure rpm V % km/h — rpm km/h °C rpm rpm A A A A A A A kPa kPa kPa kPa kPa kPa kPa A kPa ON input or OFF input ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF High or Low High or Low High or Low High or Low ON or OFF ON or OFF

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Read Current Data AUTOMATIC TRANSMISSION (DIAGNOSTICS) Item Direct clutch fluid pressure switch input signal Front brake fluid pressure switch input signal Input clutch fluid pressure switch input signal Forward brake fluid pressure switch input signal

Display D/C Fluid Pressure F/B Fluid Pressure I/C Fluid Pressure Fwd/B hydraulic pressure SW

AT learning mode

AT learning

5AT(diag)-19

Unit of measure ON or OFF ON or OFF ON or OFF ON or OFF Completed or not completed

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Read Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

8. Read Diagnostic Trouble Code (DTC) A: OPERATION For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. NOTE: For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC).

5AT(diag)-20

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Clear Memory Mode AUTOMATIC TRANSMISSION (DIAGNOSTICS)

9. Clear Memory Mode A: OPERATION For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”. NOTE: • If {Clear Memories 2} is executed, DTCs and learned control memory are cleared. • If {Clear Memories 2} is executed, perform learning.

5AT(diag)-21

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Inspection Mode AUTOMATIC TRANSMISSION (DIAGNOSTICS)

10.Inspection Mode A: PROCEDURE CAUTION: Observe the traffic law when driving on public roads. 1) Shift the select lever to “D” range, and then drive the vehicle with changing the gear from 1st to 5th. 2) When driving the vehicle at 5th speed of “D” range, set the gear to manual mode and drive the vehicle by downshifting using “–” of the paddle shift switch from 5th → 4th, 4th → 3rd, 3rd → 2nd, and 2nd → 1st. NOTE: At shifting down, drive the vehicle at least 10 seconds in each speed. 3) Shift the select lever to “R” range and drive the vehicle for 2 seconds or more.

5AT(diag)-22

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Learning Control AUTOMATIC TRANSMISSION (DIAGNOSTICS)

11.Learning Control A: GENERAL DESCRIPTION • Follow the messages displayed on the Subaru Select Monitor when working. • When the following work is performed, perform learning for the transmission. Replacement of TCM/Replacement or disassembly of transmission assembly/Replacement of control valve body/Performing “Clear Memories 2”.

B: PROCEDURE 1. PREPARATION FOR LEARNING 1) Warm up or cool down the vehicle until the ATF temperature displayed on the Subaru Select Monitor is 60 — 80°C (140 — 176°F). 2) Shift the select lever to “P” range. 3) Apply the electronic parking brake. 4) Lift up the vehicle. CAUTION: While working, be sure to keep the lower edge of the tires 30 cm or more above the ground as vehicle will vibrate. 5) Connect the Subaru Select Monitor to data link connector. 6) Turn the ignition switch to ON. 7) Select {AT related learning & inspecting mode} in the «Transmission Diagnosis» screen of the Subaru Select Monitor. 8) Select {AT learning mode} in the «AT related learning & inspecting mode» screen of the Subaru Select Monitor. 9) Follow the messages displayed on the Subaru Select Monitor screen when working.

2. SIMPLE LEARNING NOTE: Simple learning is performed with the vehicle lifted, without actually running the vehicle. CAUTION: Do not turn the power of the Subaru Select Monitor to OFF or disconnect the data link connector during the operation. 1) Follow the messages displayed on the Subaru Select Monitor screen when working. NOTE: During “SHIFT control system learning in progress” and “AWD control system learning in progress”, AT OIL TEMP light in the combination meter starts blinking at 2 Hz and the learning operation starts. The following message is displayed on the screen when the AT OIL TEMP light in the combination meter goes off. When the learning ended abnormally, AT OIL TEMP light blinks at 4 Hz.

5AT(diag)-23

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Learning Control AUTOMATIC TRANSMISSION (DIAGNOSTICS)

2) “AT learning normally ended.” is displayed, simple AT learning is completed. NOTE: • If communication error occurs during learning, retry the “AT learning mode” from the beginning. • If the message “Execute AT learning again after fixing troubles of the vehicle” is displayed during learning, select [OK] to display the List of Diagnostics Trouble Code. After repairing the locations indicated by the DTC, start the “AT learning mode” over from the beginning. • If the message “AT learning ended abnormally.” is displayed, start the “AT learning mode” over from the beginning. Message AT learning ended abnormally.

Main reasons for abnormal termination • Fault is detected during AT learning. • The accelerator pedal is depressed during AT learning. • Operation which is not directed is performed during AT learning. • Brake pedal not stepped on firmly enough. • Electronic parking brake not applied strongly enough • Abnormal idle speed increase, etc.

• For detailed operation procedures, refer to “PC application help for Subaru Select Monitor”.

3. DRIVING CHECK Drive the vehicle to check that there is no malfunction such as shifting shock. When shifting shock is felt, perform learning again. When reducing of shifting shock is not felt, check that other parts are normal.

5AT(diag)-24

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AT OIL TEMP Warning Light Display AUTOMATIC TRANSMISSION (DIAGNOSTICS)

12.AT OIL TEMP Warning Light Display A: OPERATION When any on-board diagnostics item is malfunctioning, or the learning has not yet completed, AT OIL TEMP light blinks. Blinking continues from the engine start to the ignition switch OFF. The malfunctioning part or unit can be determined by a DTC. Problems which occurred previously can also be identified through the memory function. If the AT OIL TEMP light does not blink although a problem is occurring, the problem can be determined by checking the performance characteristics of each sensor using the Subaru Select Monitor. If the learning has not yet completed, “AT learning not completed” is displayed when the Subaru Select Monitor is connected while AT OIL TEMP light is blinking. The AT OIL TEMP light blinking will go off, when the learning is performed. Indicator light signal patterns are as shown in the figure.

(A)

(1)

(2)

(1) (3)

(B) (2)

(4) (1) (C)

(3) (2) (5) (4)

(D)

(4)

(1) (3) (2) (5)

(5)

AT-05550

(A) (D)

Ignition switch (engine OFF) Learning not completed (engine ON)

(B)

Normal (engine ON)

(C)

Faulty (engine ON)

(1) (2)

ON OFF

(3) (4)

2 sec. 1 sec.

(5)

Blink

When the AT OIL TEMP light does not operate normally, check the AT OIL TEMP light circuit.

5AT(diag)-25

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AT OIL TEMP Warning Light Display AUTOMATIC TRANSMISSION (DIAGNOSTICS)

B: INSPECTION DIAGNOSIS: • AT OIL TEMP light circuit is open or shorted. • Combination meter malfunction TROUBLE SYMPTOM: • When the ignition switch is turned to ON, the AT OIL TEMP light does not illuminate. • AT OIL TEMP light remains lit after engine start. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT FB-30 F/B FUSE NO. 5 (IG)

B54

19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

AT OIL TEMP

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

COMBINATION METER

i10

20

32

21

33

i10

B 54

TCM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

AT-05311

1

2

3

4

5

6

Step CHECK AT OIL TEMP LIGHT. Turn the ignition switch to ON.

Check Does the AT OIL TEMP light illuminate?

Yes Go to step 2.

CHECK AT OIL TEMP LIGHT. After the ignition switch is ON, wait for 2 seconds or more. CHECK AT OIL TEMP LIGHT. Start the engine.

Does the AT OIL TEMP light illuminate?

Go to step 3.

Does the AT OIL TEMP light go Normal. Go back to off? “Basic Diagnostic Procedure”. CHECK SUBARU SELECT MONITOR COM- Is the communication between Go to step 5. MUNICATION. Subaru Select Monitor and Connect the Subaru Select Monitor to data link TCM normal? connector.

CHECK DTC. Is DTC displayed? Read the DTC relating the TCM using the Subaru Select Monitor. CHECK TCM. Is “ON” displayed? Read the data of “ATF Temperature Lamp” using the Subaru Select Monitor.

5AT(diag)-26

No Perform self diagnosis of the combination meter. Go to step 4.

Go to step 6.

Check the power supply ground circuit of TCM and Subaru Select Monitor communication. Go to step 6.

Perform the diagnosis according to DTC. Go to step 7. Perform self diagnosis of the combination meter.

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AT OIL TEMP Warning Light Display AUTOMATIC TRANSMISSION (DIAGNOSTICS)

7

8

Step CHECK TCM. Read the data of ATF temperature using Subaru Select Monitor.

Check Is the display 130°C or more?

No Replace the TCM.

CHECK ATF TEMPERATURE. Is the temperature lower than Perform the diag- When ATF temperCheck the real fluid temperature from the trans- “ATF temperature” displayed on nosis according to ature can be mission case surface temperature. Subaru Select Monitor? DTC P0713. judged as actually high, perform the diagnosis again after the ATF temperature lowers.

5AT(diag)-27

Yes Go to step 8.

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AWD Warning Light Display AUTOMATIC TRANSMISSION (DIAGNOSTICS)

13.AWD Warning Light Display A: OPERATION AWD warning light illuminates or blinks at start, or when AWD is faulty. • Normal AWD light always illuminates when the ignition switch is ON (engine OFF). Light goes off after two seconds from engine ON. • Faulty AWD warning light blinks at 2 Hz, when tires with different diameters are installed, or when the vehicle is driven with air pressure of any of the four tires significantly low.

(A)

(1)

(2)

(1) (3)

(B) (2)

(4) (1) (C)

(3) (2) (5) AT-05548

(A)

Ignition switch (engine OFF)

(B)

Normal (engine ON)

(C)

Faulty (engine ON)

(1) (2)

ON OFF

(3) (4)

2 sec. 1 sec.

(5)

Blink

If the AWD light does not illuminate, or illumination patterns are not as above, check the AWD light circuit.

5AT(diag)-28

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AWD Warning Light Display AUTOMATIC TRANSMISSION (DIAGNOSTICS)

B: INSPECTION DIAGNOSIS: • AWD light circuit is open or shorted. • Combination meter malfunction • TCM malfunction TROUBLE SYMPTOM: • When the ignition switch is turned to ON, the AWD light does not illuminate. • AWD light remains lit after engine start. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT

FB-30 F/B FUSE NO. 5 (IG)

i10

19

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

AWD WARNING LIGHT

COMBINATION METER B54 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

20

32

21

33

i10

B 54

TCM

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

AT-05549

Step CHECK AWD LIGHT. Turn the ignition switch to ON.

Check Yes Does the AWD light illuminate? Go to step 2.

2

CHECK AWD LIGHT. Start the engine.

3

CHECK COMBINATION METER. Perform self diagnosis of the combination meter.

Does AWD light go off after two Current condition seconds from engine start? is normal. Go back to “Basic Diagnostic Procedure”.

Is there any trouble with the Repair the combi- Replace the TCM. combination meter? nation meter.

1

5AT(diag)-29

No Perform self diagnosis of the combination meter. Go to step 3.

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Diagnostic Procedure for Subaru Select Monitor Communication AUTOMATIC TRANSMISSION (DIAGNOSTICS)

14.Diagnostic Procedure for Subaru Select Monitor Communication A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE DIAGNOSIS: Defective harness connector TROUBLE SYMPTOM: Subaru Select Monitor communication failure WIRING DIAGRAM: BATTERY

B 40

A : B 134

E

SBF-5

M/B No. 16

16 7

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 33 34 31 32

1 2 8 9 10 18 19 20 28 29 30

M/B No. 12

DATA LINK CONNECTOR

5

IGNITION SWITCH

M/B No. 17

MAIN SBF

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

C: B136

B40

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

4

4

5 6 14 15 16 25 26 27 33 34 35

3

B54

C4

B220

F/B No. 12

MAIN RELAY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

A : B134 ECM

B21

36

TCM

8

18

B 54

19

26

25

24

A6

C : B136

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

B 21

22

23

E2

34 42

35 43 48

E

36 49

37 44 50

38 45 51

39 52

40 46 53

41 47 54

B220

E

1 3 4 2

5 7 8 6

9 11 12 10

13 15 16 14

17 18 20 21 19

RELAY HOLDER

AT-05566

1

Step Check CHECK SUBARU SELECT MONITOR POW- Is the voltage 10 V or more? ER SUPPLY CIRCUIT. Measure the voltage between data link connector and chassis ground. Connector & terminal (B40) No. 16 (+) — Chassis ground (–):

5AT(diag)-30

Yes Go to step 2.

No Repair harness connector between the battery and data link connector, and poor contact of the connector.

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Diagnostic Procedure for Subaru Select Monitor Communication AUTOMATIC TRANSMISSION (DIAGNOSTICS)

2

3

4

5

6

7

8

9

10

11

Step CHECK SUBARU SELECT MONITOR GROUND CIRCUIT. Measure the resistance of harness between data link connector and chassis ground. Connector & terminal (B40) No. 4 — Chassis ground: (B40) No. 5 — Chassis ground: CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to ON. 2) Check communication with the transmission system using the Subaru Select Monitor. CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM connector. 3) Turn the ignition switch to ON. 4) Check communication with the engine system. CHECK COMMUNICATION OF SUBARU SELECT MONITOR. 1) Turn the ignition switch to OFF. 2) Connect the TCM connector. 3) Disconnect the connector from ECM. 4) Turn the ignition switch to ON. 5) Check communication with the transmission system. CHECK HARNESS CONNECTOR BETWEEN EACH CONTROL MODULE AND DATA LINK CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the TCM and ECM connector. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B40) No. 7 — Chassis ground: CHECK OUTPUT SIGNAL OF TCM. 1) Turn the ignition switch to ON. 2) Measure the voltage between TCM and chassis ground. Connector & terminal (B40) No. 7 (+) — Chassis ground (–): CHECK HARNESS CONNECTOR BETWEEN TCM AND DATA LINK CONNECTOR. Measure the resistance between TCM connector and data link connector. Connector & terminal (B54) No. 8 — (B40) No. 7: CHECK INSTALLATION OF TCM CONNECTOR. Turn the ignition switch to OFF. CHECK INSTALLATION OF TRANSMISSION HARNESS CONNECTOR.

CHECK POOR CONTACT OF CONNECTORS.

Check Yes Is the resistance less than 1 Ω? Go to step 3.

Is the name of system disGo to step 8. played on Subaru Select Monitor?

No Repair the open circuit of harness between data link connector and ground terminal, and poor contact of connector. Go to step 4.

Is the name of system disGo to step 6. played on Subaru Select Monitor?

Go to step 5.

Is the name of system disInspect the ECM. played on Subaru Select Monitor?

Go to step 6.

Is the resistance 1 MΩ or more?

Go to step 7.

Check harness and connector between each control module and data link connector.

Is the voltage 1 V or more?

Check harness Go to step 8. and connector between each control module and data link connector. Is the resistance less than 1 Ω? Go to step 9. Check the harness and connector between TCM and data link connector. Is TCM connector connected to Go to step 10. TCM?

Connect the TCM connector to TCM.

Go to step 11.

Connect the bulkhead harness connector to transmission harness connector. Go to step 12.

Is the transmission harness connector connected to bulkhead harness connector?

Is there poor contact of control Repair the poor module power supply and data contact. link connector?

5AT(diag)-31

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Diagnostic Procedure for Subaru Select Monitor Communication AUTOMATIC TRANSMISSION (DIAGNOSTICS)

12

13

14

15

16

17

18

Step CHECK POWER SUPPLY OF TCM. 1) Disconnect the connector from TCM. 2) Turn the ignition switch to ON. 3) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 24 (+) — Chassis ground (–): (B54) No. 25 (+) — Chassis ground (–): (B54) No. 26 (+) — Chassis ground (–): CHECK M/B FUSE. 1) Turn the ignition switch to OFF. 2) Remove the fuse (No. 16 and No. 17). CHECK HARNESS. Measure the resistance between TCM connector and chassis ground. Connector & terminal (B54) No. 24 — Chassis ground: (B54) No. 25 — Chassis ground: (B54) No. 26 — Chassis ground: CHECK IGNITION POWER SUPPLY CIRCUIT. 1) Turn the ignition switch to ON. 2) Measure the ignition power supply voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 18 (+) — Chassis ground (–): (B54) No. 19 (+) — Chassis ground (–): CHECK F/B FUSE. Remove the fuse (No. 12).

Check Is the voltage 10 — 13 V?

Yes Go to step 15.

No Go to step 13.

Is the fuse blown out?

Replace the fuse.

Go to step 14.

Is the resistance less than 10 Ω?

Replace the fuse. If Go to step 15. the replaced fuse blows out easily, repair the short circuit in the harness between the fuse and the TCM. Go to step 17. Go to step 16.

CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM. 3) Measure the resistance of the harness between TCM and transmission ground. Connector & terminal (B54) No. 22 — Transmission ground: (B54) No. 23 — Transmission ground: CHECK POOR CONTACT OF CONNECTORS.

Is the resistance 1 MΩ or more?

Is the voltage 10 — 13 V?

Is the fuse blown out?

Replace the fuse. If Go to step 17. the replaced fuse blows out easily, repair the short circuit in the harness between the fuse and the TCM. Repair the short Go to step 18. circuit of harness between TCM and transmission harness connector, and poor contact of connector.

Is there poor contact of TCM Repair the connec- Replace the TCM. power supply, ground and data tor.

5AT(diag)-32

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List of Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

15.List of Diagnostic Trouble Code (DTC) A: LIST DTC

Item

Content of diagnosis

Reference

P0705

Transmission Range Sensor Circuit (PRNDL Input)

Inhibitor switch malfunction, open or short circuit

P0712

Transmission Fluid Temperature Sensor Circuit Low Input

ATF temperature sensor 1 is faulty or input signal circuit is open.

P0713

Transmission Fluid Temperature Sensor Circuit High Input

ATF temperature sensor 1 is faulty or input signal circuit is shorted.

P0715

Input/Turbine Speed Sensor Circuit

Turbine speed sensor 1 malfunction, open or shorted input signal circuit

P0719

Brake switch malfunction, open input signal circuit, body inteBrake Switch Circuit Low grated unit malfunction, or CAN communication error

P0720

Output Speed Sensor Circuit

Front vehicle speed sensor malfunction, open or shorted input signal circuit, ground, power supply

P0724

Brake Switch Circuit High

Brake switch malfunction, shorted input signal circuit, body integrated unit malfunction, or CAN communication error

P0731

Gear 1 Incorrect Ratio

Vehicle speed sensor, turbine speed sensor, control valve, or gear shift clutch malfunction

P0732

Gear 2 Incorrect Ratio

P0733

Gear 3 Incorrect Ratio

P0734

Gear 4 Incorrect Ratio

P0735

Gear 5 Incorrect Ratio

P0736

Reverse Incorrect Ratio

P0741

Torque Converter Clutch Circuit Performance or Stuck Off

Lock-up clutch is faulty or valve is stuck.

P0743

Torque Converter Clutch Circuit Electrical

L/U solenoid circuit or L/U solenoid unit malfunction

Vehicle speed sensor, turbine speed sensor, control valve, or gear shift clutch malfunction Vehicle speed sensor, turbine speed sensor or gear shift clutch malfunction Vehicle speed sensor, turbine speed sensor or gear shift clutch malfunction Vehicle speed sensor, turbine speed sensor or gear shift clutch malfunction Vehicle speed sensor, turbine speed sensor or gear shift clutch malfunction

5AT(diag)-33









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2015年12月24日 木曜日 午後5時18分

List of Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS) DTC

Item

Content of diagnosis Line pressure solenoid circuit or line pressure solenoid unit malfunction

Reference

P0748

Pressure Control Solenoid “A” Electrical

P0751

Shift Solenoid “A” PerforFr/B solenoid malfunction mance or Stuck Off

P0753

Shift Solenoid “A” Electrical

P0756

Shift Solenoid “B” PerforI/C solenoid malfunction mance or Stuck Off

P0758

Shift Solenoid “B” Electrical

P0761

Shift Solenoid “C” PerforH&LR/C solenoid malfunction mance or Stuck Off

P0763

Shift Solenoid “C” Electrical

P0766

Shift Solenoid “D” PerforD/C solenoid malfunction mance or Stuck Off

P0768

Shift Solenoid “D” Electrical

P0771

Shift Solenoid “E” PerforFwd/B solenoid malfunction mance or Stuck Off

P0773

Shift Solenoid “E” Electrical

P0801

Reverse Inhibit Control Circuit

P0817

Starter Disable Circuit

P0957

Backup Light Relay Circuit Low

P0958

Backup Light Relay Circuit High

Shorted back-up light relay output circuit or relay ON malfunction

P1706

AT Vehicle Speed Sensor Circuit Malfunction (Rear wheel)

Rear vehicle speed sensor malfunction, open or shorted input circuit, ground, power supply

Fr/B solenoid circuit or Fr/B solenoid unit malfunction

I/C solenoid circuit or I/C solenoid unit malfunction



D/C solenoid circuit or D/C solenoid unit malfunction

Fwd/B solenoid circuit or Fwd/B solenoid unit malfunction



Shift lock solenoid is faulty or out- • Open or short in PN signal out • TCM+B fuse is blown. Open or shorted back-up light

5AT(diag)-34

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2015年12月24日 木曜日 午後5時18分

List of Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS) DTC

Item

Content of diagnosis

P1707

AT AWD Solenoid Valve Circuit Malfunction

AWD solenoid circuit or AWD solenoid unit malfunction

P1710

Torque Converter Turbine 2 Speed Signal Circuit Malfunction

Turbine speed sensor 2 malfunction, open or shorted input circuit, ground, power supply

P1718

AT CAN Communication Circuit

Open CAN communication bus off, shorted ECM, ABS/VDCCM, body integrated unit malfunction

P1724

AT EEPROM Error

TCM EEPROM malfunction

P1817

Sports Mode Switch Circuit (Manual Switch)

Open or shorted manual mode switch or switch malfunction

P1840

Transmission Fluid Pressure Sensor Switch A Circuit

Open or shorted Fr/B fluid pressure switch or switch malfunction

P1841

Transmission Fluid Pressure Sensor Switch B Circuit

Open or shorted Fwd/B fluid pressure switch or switch malfunction

P1842

Transmission Fluid Pressure Sensor Switch C Circuit

Open or shorted I/O fluid pressure switch or switch malfunction

P1843

Transmission Fluid Pressure Sensor Switch D Circuit

Open or shorted D/C fluid pressure switch or switch malfunction

P1844

Transmission Fluid Pressure Sensor Switch E Circuit

Open or shorted H&LR/C fluid pressure switch or switch malfunction

5AT(diag)-35

Reference







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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

16.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT) DTC DETECTING CONDITION: The inhibitor switch is open or short. TROUBLE SYMPTOM: • Shift characteristics are erroneous. • Select lever position indicator does not match with select lever. • Select lever position indicator does not illuminate. • N-D, N-R shock occur. WIRING DIAGRAM:

TO POWER SUPPLY CIRCUIT FB-30 F/B FUSE NO. 5 (IG)

T14

19

1 2 3 4 5 6

LCD SHIFT INDICATOR · SHIFT UP · SHIFT DOWN · SHIFT POSITION

I/F

B12 COMBINATION METER

1 2 3 4 5 6 7 8

i10 MICRO COMPUTER

33

32

A21

A20

CAN TRANSCEIVER & RECEIVER

A:

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

B: B 55

4 5 6 7 14 15 16 17 18 19 24 25 26 27 32 33 34 35

B55

TCM 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B11

B9

B:

B10

B54 B8

A:

B54

5 6 14 15 16 25 26 27 33 34 35

1

3

2

4

B12

6

3

5

2

T3

i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

T14

INHIBITOR SWITCH

CONTROL VALVE BODY

AT-05308

1

Step CHECK DTC OF TCM.

Check Yes No Is DTC of AT CAN communica- Perform the diag- Go to step 2. tion circuit displayed? nosis according to DTC.

5AT(diag)-36

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

2

Step CHECK INHIBITOR SWITCH. Using Subaru Select Monitor, read the data of “Inhibitor SW 1 — 4” for each range.

Check Yes Is the display as in the table of Go to step 9. step 2?

No Go to step 3.

Is the display “High” for both “P” Go to step 4. and “D”?

Go to step 7.

Is the display “High” for both “R” Go to step 5. and “D”?

Go to step 7.

Is the display “High” for both “N” Go to step 6. and “D”?

Go to step 7.

Is the display “High” for both “P” Go to step 8. and “N”?

Go to step 7.

Is the resistance less than 1 Ω? Go to step 8.

Repair the open circuit of harness between TCM connector and transmission connector.

Go to step 9.

Repair the short circuit of harness between TCM connector and transmission connector.

SW1 SW2 SW3 SW4 P R N D =High

3

4

5

6

7

8

AT-05083

CHECK INHIBITOR SWITCH. Using Subaru Select Monitor, read the data of “Inhibitor SW 1” for “P” and “D” ranges. CHECK INHIBITOR SWITCH. Using Subaru Select Monitor, read the data of “Inhibitor SW 2” for “R” and “D” ranges. CHECK INHIBITOR SWITCH. Using Subaru Select Monitor, read the data of “Inhibitor SW 3” for “N” and “D” ranges. CHECK INHIBITOR SWITCH. Using Subaru Select Monitor, read the data of “Inhibitor SW 4” for “P” and “N” ranges. CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 8 — (B12) No. 4: (B55) No. 9 — (B12) No. 3: (B55) No. 10 — (B12) No. 2: (B55) No. 11 — (B12) No. 1: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance between TCM connector and chassis ground. Connector & terminal (B55) No. 8 — Chassis ground: (B55) No. 9 — Chassis ground: (B55) No. 10 — Chassis ground: (B55) No. 11 — Chassis ground:

Is the resistance 1 MΩ or more?

5AT(diag)-37

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

9

10

11

12

Step CHECK INPUT SIGNAL CIRCUIT FOR TCM. 1) Turn the ignition switch to OFF. 2) Disconnect the transmission connector (B12). 3) Connect the TCM connector. 4) Turn the ignition switch to ON. 5) Measure the voltage between TCM terminals. Connector & terminal (B55) No. 8 (+) — (B54) No. 23 (–): (B55) No. 9 (+) — (B54) No. 23 (–): (B55) No. 10 (+) — (B54) No. 23 (–): (B55) No. 11 (+) — (B54) No. 23 (–): CHECK TCM I/O SIGNAL. Check I/O signal of power supply and ground.

CHECK INPUT SIGNAL FOR TCM. 1) Connect all connectors. 2) Lift up the vehicle. 3) Start the engine. 4) Using Subaru Select Monitor, read the data of “Front Wheel Speed” and “AT Turbine Speed 2”. NOTE: The speed difference between front and rear wheels lights the ABS warning light or the VDC warning light, but this does not indicate a malfunction. If the warning light illuminates, delete the ABS or VDC memory after completing the AT control diagnosis. CHECK INPUT SIGNAL FOR TCM. 1) Drive at 4th of manual mode. NOTE: Turbine speed sensor 1 signal can be measured only on 4th speed. 2) Using Subaru Select Monitor, read the data of “Rear Wheel Speed” and “AT Turbine Speed 1”. NOTE: The speed difference between front and rear wheels lights the ABS warning light or the VDC warning light, but this does not indicate a malfunction. If the warning light illuminates, delete the ABS or VDC memory after completing the AT control diagnosis.

Check Yes Is the voltage of “Inhibitor SW 1 Go to step 11. — 4” 8 V or more?

No Go to step 10.

Is TCM I/O signal OK?

Replace the TCM.

Does the speedometer indica- Go to step 12. tion increase as “Front Wheel Speed” and “AT Turbine Speed 2” values increase?

Repair the open or short circuit for power supply and ground.

Does the speedometer indica- Go to step 13. tion increase as “Rear Wheel Speed” and “AT Turbine Speed 1” values increase?

Repair the open circuit of harness or poor contact of connector between TCM and rear vehicle speed sensor and turbine speed sensor 1.

5AT(diag)-38

Replace the control valve body.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

13

14

15

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the connector from control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T3) No. 4 — (T14) No. 2: (T3) No. 3 — (T14) No. 3: (T3) No. 2 — (T14) No. 5: (T3) No. 1 — (T14) No. 6: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T14) No. 2 — Transmission ground: (T14) No. 3 — Transmission ground: (T14) No. 5 — Transmission ground: (T14) No. 6 — Transmission ground: CHECK FOR POOR CONTACT.

Check Yes Is the resistance less than 1 Ω? Go to step 14.

No Repair the open circuit of harness between control valve body connector and transmission connector.

Is the resistance 1 MΩ or more?

Go to step 15.

Repair the short circuit of harness between control valve body connector and transmission connector.

Is there any poor contact of “Inhibitor SW 1 — 4” monitor circuit?

Repair the poor contact.

Replace the control valve body.

5AT(diag)-39

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

B: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW INPUT DTC DETECTING CONDITION: Input signal circuit to ATF temperature sensor is open. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM: T10

TCM

1 2 3 4 5 6 7 8 9 10

17 18

B55

B11 5 12

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

ATF TEMPERATURE SENSOR 3 4

T4

5

T10 B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

CONTROL VALVE BODY

1

2

3

AT-05309

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 17 — (B11) No. 5: (B55) No. 18 — (B11) No. 12: CHECK ATF TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Connect the connectors to transmission and TCM. 3) Start the engine. 4) Warm up the transmission until the ATF temperature exceeds 80°C (176°F). 5) Disconnect the connector from transmission. 6) Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 5 — (T4) No. 12: CHECK ATF TEMPERATURE SENSOR. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 5 — (T4) No. 12:

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness between TCM connector and transmission connector.

Is the resistance 300 — 800 Ω? Go to step 3.

Go to step 5.

Go to step 4.

Go to step 5.

Does the resistance value increase as the ATF temperature decreases?

5AT(diag)-40

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4

5

6

Step CHECK INPUT SIGNAL FOR TCM. 1) Connect the connector. 2) Turn the ignition switch to ON. 3) Read the data of ATF temperature using Subaru Select Monitor.

Check Does the ATF temperature gradually decrease?

Yes Check for poor contact of the harness between the ATF temperature sensor and transmission connector, and repair the fault location. CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Replace the conTRANSMISSION AND CONTROL VALVE trol valve body. BODY.

sion. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 5 — (T10) No. 3: (T4) No. 12 — (T10) No. 4: CHECK FOR POOR CONTACT. Is there poor contact of ATF Repair the poor temperature sensor circuit? contact.

5AT(diag)-41

No Go to step 6.

Repair the open circuit of harness between transmission connector and control valve body connector.

Replace the TCM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH INPUT DTC DETECTING CONDITION: Input signal circuit to ATF temperature sensor is shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM: T10

TCM

1 2 3 4 5 6 7 8 9 10

17 18

B55

B11 5 12

B11 1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

ATF TEMPERATURE SENSOR 3 4

T4

5

T10 B55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

CONTROL VALVE BODY

1

2

3

AT-05309

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 17 — Chassis ground: (B55) No. 18 — Chassis ground: CHECK ATF TEMPERATURE SENSOR. 1) Turn the ignition switch to OFF. 2) Connect the connectors to transmission and TCM. 3) Start the engine. 4) Warm up the transmission until the ATF temperature exceeds 80°C (176°F). 5) Disconnect the connector from transmission. 6) Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 5 — (T4) No. 12: CHECK ATF TEMPERATURE SENSOR. Measure the resistance between transmission connector terminals. Connector & terminal (T4) No. 5 — (T4) No. 12:

Check Is the resistance 1 MΩ or more?

Yes Go to step 2.

No Repair the short circuit of harness between TCM connector and transmission connector.

Is the resistance 300 — 800 Ω? Go to step 3.

Go to step 5.

Go to step 4.

Go to step 5.

Does the resistance value increase as the ATF temperature decreases?

5AT(diag)-42

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4

5

6

Step CHECK INPUT SIGNAL FOR TCM. 1) Connect the connector. 2) Turn the ignition switch to ON. 3) Read the data of ATF temperature using Subaru Select Monitor.

Check Does the ATF temperature gradually decrease?

CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or TRANSMISSION AND CONTROL VALVE more? BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between chassis ground and control valve body connector. Connector & terminal (T10) No. 3 — Chassis ground: (T10) No. 4 — Chassis ground: CHECK FOR POOR CONTACT. Is there poor contact of ATF temperature sensor circuit?

5AT(diag)-43

Yes Check for poor contact of the harness between the ATF temperature sensor and transmission connector, and repair the fault location. Replace the control valve body.

No Go to step 6.

Repair the poor contact.

Replace the TCM.

Repair the short circuit of harness between transmission connector and control valve body connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT DTC DETECTING CONDITION: Input signal circuit of TCM is open or shorted. TROUBLE SYMPTOM: • Excessive shift shock • Does not shift to 5th. WIRING DIAGRAM: AT1

TCM 1

2

3

B12

26

16 27

B55

1 2 3 4 5 6 7 8 B12

B11

7

2 7

B11

T3

T4

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 1 2

2

1 3

5

B55 AT1

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

TURBINE SPEED SENSOR 1

1

2

3

4

Step CHECK TCM I/O SIGNAL. Check I/O signal of power supply and ground.

CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. 1) Disconnect the connectors from TCM and transmission. 2) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 16 — (B11) No. 2: (B55) No. 26 — (B12) No. 7: (B55) No. 27 — (B11) No. 7: CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 16 — Chassis ground: (B55) No. 26 — Chassis ground: (B55) No. 27 — Chassis ground: CHECK TCM POWER SUPPLY OUTPUT. 1) Connect the connector to TCM. (Transmission connector is disconnected) 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B11) No. 7 (+) — Chassis ground (–):

5 6 14 15 16 25 26 27 33 34 35

AT-05310

Check Is TCM I/O signal OK?

Yes Go to step 2.

No Repair the open or short circuit for power supply and ground.

Is the resistance less than 1 Ω? Go to step 3.

Repair the open circuit of harness between TCM connector and transmission connector.

Is the resistance 1 MΩ or more?

Go to step 4.

Repair the short circuit of harness between TCM connector and transmission connector.

Is the voltage 10 — 13 V?

Go to step 5.

Replace the TCM.

5AT(diag)-44

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5

6

7

8

9

Step CHECK TURBINE SPEED SENSOR FOR TCM. Measure the voltage between TCM connector terminals. Connector & terminal (B12) No. 7 (+) — (B11) No. 2 (–): CHECK HARNESS ASSEMBLY (TURBINE SPEED SENSOR GROUND). Check the installing condition of ground connecting harness of harness assembly (used for both of turbine speed sensor 1, rear vehicle speed sensor).

Check Is the voltage 4 — 6 V?

Yes Go to step 6.

No Replace the TCM.

Is the ground connecting harness installed to transmission body correctly, or the harness and terminals not damaged?

Go to step 7.

CHECK HARNESS ASSEMBLY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Disconnect the connector from turbine speed sensor 1. 4) Measure the resistance between transmission connector and turbine speed sensor 1 connector. Connector & terminal (T3) No. 7 — (AT1) No. 2: (T4) No. 7 — (AT1) No. 3: (T4) No. 2 — (AT1) No. 1: CHECK HARNESS ASSEMBLY. Measure the resistance between transmission connector and chassis ground. Connector & terminal (T3) No. 7 — Chassis ground: (T4) No. 7 — Chassis ground: (T4) No. 2 — Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect all connectors. 2) Lift up the vehicle. 3) Start the engine. 4) Drive at 4th of manual mode. NOTE: Turbine speed sensor 1 signal can be measured only on 4th speed. 5) Using Subaru Select Monitor, read the data of “AT Turbine Speed 1”. NOTE: The speed difference between front and rear wheels lights the ABS warning light or the VDC warning light, but this does not indicate a malfunction. If the warning light illuminates, delete the ABS or VDC memory after completing the AT control diagnosis.

Is the resistance less than 1 Ω? Go to step 8.

When poor installation of ground occurs, install it securely. Replace the transmission assembly if the harness or terminal is damaged.

Repair the open circuit of harness or poor contact of connector between TCM connector and transmission connector.

Is the resistance 1 MΩ or more?

Go to step 9.

Repair the short circuit of harness between TCM connector and transmission connector.

Are the values of “AT Turbine Speed 1” and “AT Turbine Speed 2” almost the same?

Check for poor contact of the harness between the ATF temperature sensor and transmission connector, and repair the fault location.

Replace the turbine speed sensor 1.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

E: DTC P0719 BRAKE SWITCH CIRCUIT LOW DTC DETECTING CONDITION: Brake switch malfunction, open input signal circuit TROUBLE SYMPTOM: Brake down control does not operate in manual mode. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT

*1

B512

B65

FB-2 F/B FUSE NO. 8 (B)

1 3

*1

J/C B512

2

1 2 3 4 5 6 7 8

2 4

3

A : B280

STOP LIGHT & BRAKE SWITCH

*2

B 65 J/C

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

*2

B512

A10

B : B281

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 5 AND 6

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B54

B54

20

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 3, 4, 7 AND 8

21

*1 *2

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

B28

B20

A : B280

BODY B : B281 INTEGRATED UNIT

TCM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35

AT-05567

Step

Check Is any of following DTC displayed? / AT CAN Communication Circuit / Output Speed Sensor Circuit / AT Vehicle Speed Sensor Circuit Malfunction (Rear Wheel) / VDC Brake SW Circuit Is “ON” displayed?

1

CHECK DTC.

2

CHECK BODY INTEGRATED UNIT. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON. 4) Run the Subaru Select Monitor. 5) Depress the brake pedal. 6) Read the data of “Stop Light Switch” using Subaru Select Monitor. CHECK TCM. Is “ON” displayed? Read the data of “Stop Light Switch” using Subaru Select Monitor.

3

5AT(diag)-46

Yes No Perform the diag- Go to step 2. nosis according to DTC.

Go to step 3.

Go to step 4.

A temporary poor contact of connector or harness may be the cause. Check the poor contact.

Replace the TCM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4

5

6

7

Step CHECK BODY INTEGRATED UNIT INPUT SIGNAL. 1) Disconnect the connector from body integrated unit. 2) Depress the brake pedal. 3) Measure the voltage between body integrated unit connector and chassis ground. Connector & terminal (B280) No. 10 (+) — Chassis ground (–): CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND STOP LIGHT SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from stop light switch. 3) Measure the resistance of harness between body integrated unit connector and stop light switch connector. Connector & terminal (B280) No. 10 — (B65) No. 3: CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND STOP LIGHT SWITCH. Measure the resistance of harness between body integrated unit connector and stop light switch connector. Connector & terminal (B280) No. 10 — Chassis ground: CHECK FOR POOR CONTACT.

Check Is the voltage 10 V or more?

Yes Go to step 7.

No Go to step 5.

Is the resistance less than 1 Ω? Go to step 6.

Repair the open circuit of harness between body integrated unit connector and stop light switch connector.

Is the resistance 1 MΩ or more?

Go to step 7.

Repair the short circuit of harness between body integrated unit connector and stop light switch connector.

Is there poor contact of input signal of brake switch?

Repair the poor contact.

Check body integrated unit.

5AT(diag)-47

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT DTC DETECTING CONDITION: • AT vehicle speed signal is abnormal. • The harness connector between TCM and vehicle speed sensor is open or shorted. TROUBLE SYMPTOM: • Shifting quality malfunction • Driving performance is poor. WIRING DIAGRAM: TCM

T 15

T14

T10

3 2 1

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9 10

16 27

24

B 55

B11

2 7

1

B 11 T4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

4 1

T10

2

5

T14

1 3

2

CONTROL VALVE BODY

T15

B55 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

FRONT VEHICLE SPEED SENSOR

AT-05312

1

2

3

4

Step CHECK TCM I/O SIGNAL. Check I/O signal of power supply and ground.

CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. 1) Disconnect the connectors from TCM and transmission. 2) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 16 — (B11) No. 2: (B55) No. 24 — (B11) No. 1: (B55) No. 27 — (B11) No. 7: CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 24 — Chassis ground: CHECK TCM POWER SUPPLY OUTPUT. 1) Connect the connector to TCM. (Transmission connector is disconnected) 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B11) No. 7 (+) — Chassis ground (–):

Check Is TCM I/O signal OK?

Yes Go to step 2.

No Repair the open or short circuit for power supply and ground.

Is the resistance less than 1 Ω? Go to step 3.

Repair the open circuit of harness between TCM connector and transmission connector.

Is the resistance 1 MΩ or more?

Go to step 4.

Repair the short circuit of harness between TCM connector and transmission connector.

Is the voltage 10 — 13 V?

Go to step 5.

Replace the TCM.

5AT(diag)-48

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5

6

7

8

9

Step CHECK TURBINE SPEED SENSOR FOR TCM. Measure the voltage change between TCM connector terminals. Connector & terminal (B11) No. 1 (+) — (B11) No. 2 (–): CHECK INPUT SIGNAL FOR TCM. 1) Connect all connectors. 2) Lift up the vehicle. 3) Start the engine. 4) Read the data of “Front Wheel Speed” using Subaru Select Monitor. NOTE: The speed difference between front and rear wheels lights the ABS warning light or the VDC warning light, but this does not indicate a malfunction. If the warning light illuminates, delete the ABS or VDC memory after completing the AT control diagnosis. CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 1 — (T10) No. 2: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T10) No. 2 — Transmission ground: CHECK HARNESS CONNECTOR BETWEEN CONTROL VALVE BODY AND VEHICLE SPEED SENSOR. 1) Disconnect the connector from vehicle speed sensor. 2) Measure the resistance of harness between control valve body connector and vehicle speed sensor connector. Connector & terminal (T10) No. 2 — (T15) No. 2: (T14) No. 1 — (T15) No. 3: (T14) No. 4 — (T15) No. 1:

Check Is the voltage 4 — 6 V?

Yes Go to step 6.

No Replace the TCM.

Does the speedometer indica- Check for poor Go to step 7. tion increase as “Front Wheel contact of the harSpeed” data increases? ness between the ATF temperature sensor and transmission connector, and repair the fault location.

Is the resistance less than 1 Ω? Go to step 8.

Repair the open circuit of harness between control valve body connector and transmission connector.

Go to step 9.

Repair the short circuit of harness between transmission connector and transmission ground.

Is the resistance 1 MΩ or more?

Is the resistance less than 1 Ω? Go to step 10.

5AT(diag)-49

Replace the control valve body.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

10

Step Check CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or CONTROL VALVE BODY AND VEHICLE more? SPEED SENSOR. Measure the resistance of harness between control valve body connector and transmission ground. Connector & terminal (T10) No. 2 — Transmission ground:

5AT(diag)-50

Yes Replace the vehicle speed sensor.

No Replace the control valve body.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

G: DTC P0724 BRAKE SWITCH CIRCUIT HIGH DTC DETECTING CONDITION: Brake switch malfunction, open input signal circuit TROUBLE SYMPTOM: Gear is not shifted down when climbing a hill. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT

*1

B512

B65

FB-2 F/B FUSE NO. 8 (B)

1 3

*1

J/C B512

2

1 2 3 4 5 6 7 8

2 4

3

A : B280

STOP LIGHT & BRAKE SWITCH

*2

B 65 J/C

1 2 8 9 10 18 19 20 28 29 30

3 4 5 6 7 11 12 13 14 15 16 17 21 22 23 24 25 26 27 31 32 33 34

*2

B512

A10

B : B281

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 5 AND 6

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

B54

B54

20

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 3, 4, 7 AND 8

21

*1 *2

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

B28

B20

A : B280

BODY B : B281 INTEGRATED UNIT

TCM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 20 21 22 23 28 29 30 31 32 33 34 35

AT-05567

Step

Check Is any of following DTC detected? / AT CAN Communication Circuit / Output Speed Sensor Circuit / AT Vehicle Speed Sensor Circuit Malfunction (Rear Wheel) / VDC Brake SW Circuit Is “OFF” displayed?

1

CHECK DTC.

2

CHECK BODY INTEGRATED UNIT. 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON. 4) Run the Subaru Select Monitor. 5) Read the data of “Stop Light Switch” using Subaru Select Monitor. CHECK TCM. Is “OFF” displayed? Read the data of “Stop Light Switch” using Subaru Select Monitor.

3

5AT(diag)-51

Yes No Perform the diag- Go to step 2. nosis according to DTC.

Go to step 3.

Go to step 4.

A temporary poor contact of connector or harness may be the cause. Check the poor contact.

Replace the TCM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4

5

6

7

Step CHECK BODY INTEGRATED UNIT INPUT SIGNAL. 1) Disconnect the connector from body integrated unit. 2) Measure the voltage between body integrated unit connector and chassis ground. Connector & terminal (B280) No. 10 (+) — Chassis ground (–): CHECK STOP LIGHT SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from stop light switch. 3) Measure the resistance of harness between stop light switch connectors. Connector & terminal (B65) No. 3 — (B65) No. 2: CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND STOP LIGHT SWITCH. 1) Turn the ignition switch to ON. 2) Measure the voltage of harness between body integrated unit connector and chassis ground. Connector & terminal (B280) No. 10 (+) — Chassis ground (–): CHECK FOR POOR CONTACT.

Check Is the voltage 10 V or more?

Yes Go to step 5.

No Go to step 7.

Is the resistance 1 MΩ or more?

Go to step 6.

Replace the stop light switch.

Is the voltage less than 1 V?

Go to step 7.

Repair the short circuit of harness between TCM connector and stop light switch connector.

Is there poor contact of input signal of brake switch?

Repair the poor contact.

Check body integrated unit.

H: DTC P0731 GEAR 1 INCORRECT RATIO NOTE: Refer to DTC P0736 for diagnostic procedure.

I:

DTC P0732 GEAR 2 INCORRECT RATIO

NOTE: Refer to DTC P0736 for diagnostic procedure.

J: DTC P0733 GEAR 3 INCORRECT RATIO NOTE: Refer to DTC P0736 for diagnostic procedure.

K: DTC P0734 GEAR 4 INCORRECT RATIO NOTE: Refer to DTC P0736 for diagnostic procedure.

L: DTC P0735 GEAR 5 INCORRECT RATIO NOTE: Refer to DTC P0736 for diagnostic procedure.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

M: DTC P0736 REVERSE INCORRECT RATIO DTC DETECTING CONDITION: Target gear ratio and actual gear ratio do not match. TROUBLE SYMPTOM: • Shift point is too high or too low. • Excessive shift shock • Gear is not changed. • The vehicle does not move in “D” or “R” range with the engine running at high speed. Step

Check Is any of the following DTCs displayed? P0751, P0753, P0756, P0758, P0761, P0763, P0766, P0768, P0771, P0773 Is DTC P1718 displayed?

1

CHECK DTC.

2

CHECK DTC.

3

CHECK AT TURBINE SPEED SENSOR CIRCUIT. Perform diagnosis according to DTC P0715.

CHECK AT TURBINE SPEED SENSOR CIRCUIT. Perform diagnosis according to DTC P1710.

CHECK AT VEHICLE SPEED SENSOR CIRCUIT. Perform diagnosis according to DTC P0720.

CHECK AT VEHICLE SPEED SENSOR CIRCUIT. Perform diagnosis according to DTC P1706.

CHECK TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT). Perform diagnosis according to DTC P0705.

4

5

6

7

Is there any trouble?

Yes No Perform the diag- Go to step 2. nosis according to DTC. Perform the diag- Go to step 3. nosis according to DTC. Check the turbine Go to step 4. speed sensor 1 circuit.

Is there any trouble?

Check the turbine Go to step 5. speed sensor 2 circuit.

Is there any trouble?

Check for poor Go to step 6. contact of the front vehicle speed sensor circuit harness and repair the fault location. Check for poor Go to step 7. contact of the rear vehicle speed sensor circuit harness and repair the fault location.

Is there any trouble?

Is there any trouble?

5AT(diag)-53

Check the inhibitor There are malfuncswitch circuit. tions in TCM, TCM connector poor contact, or transmission assembly mechanical malfunction.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

N: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR STUCK OFF DTC DETECTING CONDITION: • Lock up clutch malfunction • Defective torque converter assembly • Defective control valve • Defective turbine speed sensor 1 or 2 TROUBLE SYMPTOM: No lock-up occurs. (After engine is warmed up) 1

2

Step CHECK DTC OF TCM.

Check Is any DTC of the followings detected? P0715, P0720, P0753, P0758, P0763, P0768, P0773, P0751, P0756, P0761, P0766, P0771, P1710, P1718 DRIVING CHECK FOR LOCK-UP CONDIIs the difference between TION. “Engine Speed” and “Turbine 1) Perform the Clear Memory Mode. Revolution Speed” within 2) While keeping “Accel. Opening Angle” dis- 100 rpm? played on Subaru Select Monitor, drive at 85 km/h or more. 3) Check that “L/U Solenoid Current” is 0.6 A or more by using Subaru Select Monitor. 4) Read the data of “Engine Speed” and “Turbine Revolution Speed” using Subaru Select Monitor.

5AT(diag)-54

Yes No Perform the diag- Go to step 2. nosis according to each DTC.

Temporary poor contact or open circuit occurs. Recheck that the harness connector has no faulty.

Replace the transmission assembly when the difference is 100 rpm or more, or DTC P0741 is displayed. When DTC other than P0741 is displayed, perform the diagnosis corresponding to the DTC.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

O: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL DTC DETECTING CONDITION: The output signal circuit of lock up solenoid is open or shorted. TROUBLE SYMPTOM: No lock-up occurs. (After engine is warmed up) WIRING DIAGRAM: B11

T11

20

B55

TCM

1 2 3 4 5 6 7 8

5

B:

E

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

LOCK-UP PRESSURE LINEAR SOLENOID CONTROL VALVE BODY

2

B54

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

T4

1

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

A:

B11

T11

1 2

5

A22

B:

A23

B54

B7

A:

5 6 14 15 16 25 26 27 33 34 35

AT-05314

Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 7 — (B11) No. 20: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 7 — Chassis ground:

5AT(diag)-55

No Repair the open circuit of harness between TCM connector and transmission connector.

Repair the short circuit of harness between TCM connector and transmission connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3

4

5

6

7

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. NOTE: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 20 — (T11) No. 5: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 5 — Transmission ground: CHECK LOCK-UP SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 5 — Transmission ground: CHECK FOR POOR CONTACT. Check the TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while and read DTC.

Check Yes Is the resistance less than 1 Ω? Go to step 4.

No Repair the open circuit of harness between transmission connector and control valve body connector.

Is the resistance 1 MΩ or more?

Repair the open circuit of harness between control valve body connector and transmission ground.

Go to step 5.

Is the resistance 3 — 9 Ω?

Go to step 6.

Replace the control valve body.

Go to step 7.

Is there poor contact, loosing Repair the poor terminal, entering foreign mat- contact. ter, or damaging connector body? Is DTC displayed? Replace the TCM.

5AT(diag)-56

Temporary poor contact or open circuit occurs. Recheck that the harness connector has no faulty.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

P: DTC P0748 PRESSURE CONTROL SOLENOID “A” ELECTRICAL DTC DETECTING CONDITION: Output signal circuit of line pressure solenoid is open or shorted. TROUBLE SYMPTOM: Excessive shift shock WIRING DIAGRAM: B11

T11

19

B55

TCM

1 2 3 4 5 6 7 8

1

B:

E

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

LINE PRESSURE LINEAR SOLENOID CONTROL VALVE BODY

2

B54

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

T4

1

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

A:

B11

T11

1 2

5

A22

B:

A23

B54

B6

A:

5 6 14 15 16 25 26 27 33 34 35

AT-05315

Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 6 — (B11) No. 19: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance between TCM connector and chassis ground. Connector & terminal (B55) No. 6 — Chassis ground:

5AT(diag)-57

No Repair the open circuit of harness between TCM connector and transmission connector.

Repair the short circuit of harness between TCM connector and transmission connector.

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3

4

5

6

7

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 19 — (T11) No. 1: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 1 — Transmission ground: CHECK LINE PRESSURE SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 1 — Transmission ground: CHECK FOR POOR CONTACT. Check the TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while and read DTC.

Check Yes Is the resistance less than 1 Ω? Go to step 4.

No Repair the open circuit of harness between transmission connector and control valve body connector.

Is the resistance 1 MΩ or more?

Repair the open circuit of harness between control valve body connector and transmission ground.

Go to step 5.

Is the resistance 3 — 9 Ω?

Go to step 6.

Replace the control valve body.

Go to step 7.

Is there poor contact, loosing Repair the poor terminal, entering foreign mat- contact. ter, or damaging connector body? Is DTC displayed? Replace the TCM.

5AT(diag)-58

Temporary poor contact or open circuit occurs. Recheck that the harness connector has no faulty.

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59 ページ

2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Q: DTC P0751 SHIFT SOLENOID “A” PERFORMANCE OR STUCK OFF DTC DETECTING CONDITION: Output signal of front brake solenoid does not match with oil pressure. TROUBLE SYMPTOM: Locked to 1st gear. WIRING DIAGRAM:

B55

FRONT BRAKE OIL PRESSURE SWITCH

8

7

T4

T11

T10

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10

A:

17

3

B11

T10

T11

B11

TCM

A22

B:

A23

B54

B4

B15

A:

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

B54

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

E

B:

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

FRONT BRAKE LINEAR SOLENOID

CONTROL VALVE BODY

5 6 14 15 16 25 26 27 33 34 35

AT-05316

1

2

3

4

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 4 — (B11) No. 17: (B55) No. 15 — (B11) No. 3: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 4 — Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of “F/B Fluid Pressure” using Subaru Select Monitor. CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to OFF. 2) Start the engine. 3) Shift to 1st speed while checking the current gear position using Subaru Select Monitor. 4) Read the data of “F/B Fluid Pressure” using Subaru Select Monitor.

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness between TCM connector and transmission connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the short circuit of harness between TCM connector and transmission connector.

Is “OFF” displayed?

Go to step 4.

Go to step 6.

Is “ON” displayed?

Check for poor Go to step 5. contact of harness in the solenoid output and oil pressure SW input, and repair the fault location.

5AT(diag)-59

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5

6

Step Check CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (B11) No. 3 — (T10) No. 7: (B11) No. 17 — (T11) No. 8: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or TRANSMISSION AND CONTROL VALVE more? BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T10) No. 7 — Transmission ground:

5AT(diag)-60

Yes Replace the control valve body.

No Replace the transmission harness assembly.

Replace the control valve body.

Replace the transmission harness assembly.

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

R: DTC P0753 SHIFT SOLENOID “A” ELECTRICAL DTC DETECTING CONDITION: Output signal circuit of front brake solenoid is open or shorted. TROUBLE SYMPTOM: Locked to 1st gear. WIRING DIAGRAM: B11

T11 B55

TCM

1 2 3 4 5 6 7 8

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

A22

B:

A23

B54

B4

A:

B11

B54

17

A:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

8

T4

T11

E

B:

FRONT BRAKE LINEAR SOLENOID CONTROL VALVE BODY

1

2

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

AT-05317

Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 4 — (B11) No. 17: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 4 — Chassis ground:

5AT(diag)-61

No Repair the open circuit of harness between TCM connector and transmission connector.

Repair the short circuit of harness between TCM connector and transmission connector.

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62 ページ

2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3

4

5

6

7

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 17 — (T11) No. 8: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 8 — Transmission ground: CHECK FRONT BRAKE SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 8 — Transmission ground: CHECK FOR POOR CONTACT. Check the TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while and read DTC.

Check Yes Is the resistance less than 1 Ω? Go to step 4.

No Repair the open circuit of harness between transmission connector and control valve body connector.

Is the resistance 1 MΩ or more?

Repair the open circuit of harness between control valve body connector and transmission ground.

Go to step 5.

Is the resistance 3 — 9 Ω?

Go to step 6.

Replace the control valve body.

Go to step 7.

Is there poor contact, loosing Repair the poor terminal, entering foreign mat- contact. ter, or damaging connector body? Is DTC displayed? Replace the TCM.

5AT(diag)-62

Temporary poor contact or open circuit occurs. Recheck that the harness connector has no faulty.

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

S: DTC P0756 SHIFT SOLENOID “B” PERFORMANCE OR STUCK OFF DTC DETECTING CONDITION: Output signal value of input clutch solenoid and oil pressure does not match. TROUBLE SYMPTOM: Locked to 1st or 4th gear. WIRING DIAGRAM:

INPUT CLUTCH OIL PRESSURE SWITCH

18 3

8

11

B11

T10

T10

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10

B11

A:

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

B54

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 26 27 20 21 22 23 24 25 28 29 30 31 32 33 34 35

T4

T11

T11

TCM

A23

B55

A22

B:

B54

B3

B20

A:

E

B:

INPUT CLUTCH LINEAR SOLENOID

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

5 6 14 15 16 25 26 27 33 34 35

CONTROL VALVE BODY

AT-05318

1

2

3

4

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 3 — (B11) No. 18: (B55) No. 20 — (B11) No. 11: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 20 — Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of “I/C Fluid Pressure” using Subaru Select Monitor. CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to OFF. 2) Start the engine. 3) Drive the vehicle on 4th speed of manual mode with checking current gear position using Subaru Select Monitor. 4) Read the data of “I/C Fluid Pressure” using Subaru Select Monitor.

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness between TCM connector and transmission connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the short circuit of harness between TCM connector and transmission connector.

Is “OFF” displayed?

Go to step 4.

Go to step 6.

Is “ON” displayed?

Check for poor Go to step 5. contact of harness in the solenoid output and oil pressure SW input, and repair the fault location.

5AT(diag)-63

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5

6

Step Check CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 11 — (T10) No. 8: (T4) No. 18 — (T11) No. 3: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or TRANSMISSION AND CONTROL VALVE more? BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T10) No. 8 — Transmission ground:

5AT(diag)-64

Yes Replace the control valve body.

No Replace the transmission harness assembly.

Replace the control valve body.

Replace the transmission harness assembly.

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

T: DTC P0758 SHIFT SOLENOID “B” ELECTRICAL DTC DETECTING CONDITION: Output signal circuit of input clutch solenoid is open or shorted. TROUBLE SYMPTOM: Locked to 1st or 4th gear. WIRING DIAGRAM: B11

T11

18

B55

TCM

1 2 3 4 5 6 7 8

B54

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

T4

3

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

A:

B11

T11

1 2

5

A22

B:

A23

B54

B3

A:

E

B:

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

INPUT CLUTCH LINEAR SOLENOID CONTROL VALVE BODY

5 6 14 15 16 25 26 27 33 34 35

AT-05319

1

2

Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 3 — (B11) No. 18: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance of harness between TCM connector and body harness. Connector & terminal (B55) No. 3 — Chassis ground:

5AT(diag)-65

No Repair the open circuit of harness between TCM connector and transmission connector.

Repair the short circuit of harness between TCM connector and transmission connector.

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66 ページ

2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3

4

5

6

7

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 18 — (T11) No. 3: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 3 — Transmission ground: CHECK INPUT CLUTCH SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 3 — Transmission ground: CHECK FOR POOR CONTACT. Check the TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while and read DTC.

Check Yes Is the resistance less than 1 Ω? Go to step 4.

No Repair the open circuit of harness between transmission connector and control valve body connector.

Is the resistance 1 MΩ or more?

Repair the open circuit of harness between control valve body connector and transmission ground.

Go to step 5.

Is the resistance 3 — 9 Ω?

Go to step 6.

Replace the control valve body.

Go to step 7.

Is there poor contact, loosing Repair the poor terminal, entering foreign mat- contact. ter, or damaging connector body? Is DTC displayed? Replace the TCM.

5AT(diag)-66

Temporary poor contact or open circuit occurs. Recheck that the harness connector has no faulty.

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67 ページ

2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

U: DTC P0761 SHIFT SOLENOID “C” PERFORMANCE OR STUCK OFF DTC DETECTING CONDITION: Output signal value of high & low reverse clutch solenoid and oil pressure do not match. TROUBLE SYMPTOM: Locked to 1st gear. WIRING DIAGRAM: B55

2

6

T4

HIGH & LOW REVERSE CLUTCH OIL PRESSURE SWITCH

T11

HIGH & LOW REVERSE CLUTCH LINEAR SOLENOID

T10

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10

A:

15

4

B11

T10

T11

2

3

4

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

B54

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

E

B:

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

CONTROL VALVE BODY

1

B11

TCM

A22

B:

A23

B54

B5

B14

A:

5 6 14 15 16 25 26 27 33 34 35

AT-05320

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 5 — (B11) No. 15: (B55) No. 14 — (B11) No. 4: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 14 — Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of “H&LR/C Fluid Pressure” using Subaru Select Monitor. CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to OFF. 2) Start the engine. 3) Set the select lever to “N” range while depressing the brake pedal. 4) Read the data of “H&LR/C Fluid Pressure” using Subaru Select Monitor.

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness between TCM connector and transmission connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the short circuit of harness between TCM connector and transmission connector.

Is “OFF” displayed?

Go to step 4.

Go to step 6.

Does the display show “OFF”? Check for poor Go to step 5. contact of harness in the solenoid output and oil pressure SW input, and repair the fault location.

5AT(diag)-67

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5

6

Step Check CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 4 — (T10) No. 6: (T4) No. 15 — (T11) No. 2: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or TRANSMISSION AND CONTROL VALVE more? BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T10) No. 6 — Transmission ground:

5AT(diag)-68

Yes Replace the control valve body.

No Replace the transmission harness assembly.

Replace the control valve body.

Replace the transmission harness assembly.

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

V: DTC P0763 SHIFT SOLENOID “C” ELECTRICAL DTC DETECTING CONDITION: Output signal circuit of high & low reverse clutch solenoid is open or shorted. TROUBLE SYMPTOM: Locked to 1st gear. WIRING DIAGRAM: B11

T11 TCM

A23

B55

1 2 3 4 5 6 7 8

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

A22

B:

B54

B5

A:

A:

B54

15

B11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

2

T4

T11

B:

E

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

HIGH & LOW REVERSE CLUTCH LINEAR SOLENOID

5 6 14 15 16 25 26 27 33 34 35

CONTROL VALVE BODY

AT-05321

1

2

Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 5 — (B11) No. 15: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 5 — Chassis ground:

5AT(diag)-69

No Repair the open circuit of harness between TCM connector and transmission connector.

Repair the short circuit of harness between TCM connector and transmission connector.

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3

4

5

6

7

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 15 — (T11) No. 2: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 2 — Transmission ground: CHECK HIGH & LOW REVERSE CLUTCH SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 2 — Transmission ground: CHECK FOR POOR CONTACT. Check the TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while and read DTC.

Check Yes Is the resistance less than 1 Ω? Go to step 4.

No Repair the open circuit of harness between transmission connector and control valve body connector.

Is the resistance 1 MΩ or more?

Repair the open circuit of harness between control valve body connector and transmission ground.

Go to step 5.

Is the resistance 3 — 9 Ω?

Go to step 6.

Replace the control valve body.

Is there poor contact, loosing Repair the poor terminal, entering foreign mat- contact. ter, or damaging connector body? Is DTC displayed? Replace the TCM.

5AT(diag)-70

Go to step 7.

Temporary poor contact or open circuit occurs. Recheck that the harness connector has no faulty.

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2015年12月24日 木曜日 午後5時18分

Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

W: DTC P0766 SHIFT SOLENOID “D” PERFORMANCE OR STUCK OFF DTC DETECTING CONDITION: Output signal value of direct clutch solenoid and oil pressure does not match. TROUBLE SYMPTOM: Locked to 1st or 4th gear. WIRING DIAGRAM: B55

16

10

4

9

DIRECT CLUTCH OIL PRESSURE SWITCH

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 9 10

B11

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

B54

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

T4

T11

T10

A:

B11

T10

T11

TCM

A22

B:

A23

B54

B1

B22

A:

E

B:

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

DIRECT CLUTCH LINEAR SOLENOID

5 6 14 15 16 25 26 27 33 34 35

CONTROL VALVE BODY

AT-05322

1

2

3

4

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 1 — (B11) No. 16: (B55) No. 22 — (B11) No. 10: CHECK HARNESS CONNECTOR BETWEEN TCM AND BODY HARNESS. Measure the resistance of harness between TCM connector and body harness. Connector & terminal (B55) No. 22 — Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of “D/C Fluid Pressure” using Subaru Select Monitor. CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to OFF. 2) Start the engine. 3) Shift to 2nd speed of manual mode and depress the brake with checking current gear position using Subaru Select Monitor. 4) Read the data of “D/C Fluid Pressure” using Subaru Select Monitor.

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness between TCM connector and transmission connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the short circuit of harness between TCM connector and transmission connector.

Is “OFF” displayed?

Go to step 4.

Go to step 6.

Is “ON” displayed?

Check for poor Go to step 5. contact of harness in the solenoid output and oil pressure SW input, and repair the fault location.

5AT(diag)-71

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5

6

Step Check CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 10 — (T10) No. 9: (T4) No. 16 — (T11) No. 4: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or TRANSMISSION AND CONTROL VALVE more? BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T10) No. 9 — Transmission ground:

5AT(diag)-72

Yes Replace the control valve body.

No Replace the transmission harness assembly.

Replace the control valve body.

Replace the transmission harness assembly.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

X: DTC P0768 SHIFT SOLENOID “D” ELECTRICAL DTC DETECTING CONDITION: The output signal circuit of direct clutch solenoid is open or shorted. TROUBLE SYMPTOM: Locked to 1st or 4th gear. WIRING DIAGRAM: B11

T11

16

B55

TCM

1 2 3 4 5 6 7 8

4

B:

E

5 6 14 15 16 25 26 27 33 34 35

B55

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

DIRECT CLUTCH LINEAR SOLENOID CONTROL VALVE BODY

2

B54

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

T4

1

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

A:

B11

T11

1 2

5

A22

B:

A23

B54

B1

A:

AT-05323

Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 1 — (B11) No. 16: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or Go to step 3. TCM AND CHASSIS GROUND. more? Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 1 — Chassis ground:

5AT(diag)-73

No Repair the open circuit of harness between TCM connector and transmission connector.

Repair the short circuit of harness between TCM connector and transmission connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3

4

5

6

7

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 16 — (T11) No. 4: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 4 — Transmission ground: CHECK DIRECT CLUTCH SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 4 — Transmission ground: CHECK FOR POOR CONTACT. Check the TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while and read DTC.

Check Yes Is the resistance less than 1 Ω? Go to step 4.

No Repair the open circuit of harness between transmission connector and control valve body connector.

Is the resistance 1 MΩ or more?

Repair the open circuit of harness between control valve body connector and transmission ground.

Go to step 5.

Is the resistance 3 — 9 Ω?

Go to step 6.

Replace the control valve body.

Go to step 7.

Is there poor contact, loosing Repair the poor terminal, entering foreign mat- contact. ter, or damaging connector body? Is DTC displayed? Replace the TCM.

5AT(diag)-74

Temporary poor contact or open circuit occurs. Recheck that the harness connector has no faulty.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Y: DTC P0771 SHIFT SOLENOID “E” PERFORMANCE OR STUCK OFF DTC DETECTING CONDITION: Output signal value of forward brake solenoid does not match with oil pressure. TROUBLE SYMPTOM: Locked to 2nd, 3rd or 4th gear. WIRING DIAGRAM: B55

1 2 3 4 5 6 7 8 9 10

7

T11

E

B:

2

3

4

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

B54

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

FORWARD BRAKE LINEAR SOLENOID

CONTROL VALVE BODY

1

1 2

5

13

9 10

1 2 3 4 5 6 7 8

B11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

T4

FORWARD BRAKE OIL PRESSURE SWITCH

T10

A:

B11

T10

T11

TCM

A23

B:

A22

B54

B19

B21

A:

5 6 14 15 16 25 26 27 33 34 35

AT-05324

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 19 — (B11) No. 13: (B55) No. 21 — (B11) No. 9: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance between TCM connector and chassis ground. Connector & terminal (B55) No. 21 — Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Read the data of “Fwd/B hydraulic pressure SW” using Subaru Select Monitor. CHECK INPUT SIGNAL FOR TCM. 1) Turn the ignition switch to OFF. 2) Start the engine. 3) Drive the vehicle on 2nd speed of manual mode at 15 km/h (9 MPH) with checking current gear position using Subaru Select Monitor. 4) Read the data of “Fwd/B hydraulic pressure SW” using Subaru Select Monitor.

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness between TCM connector and transmission connector.

Is the resistance 1 MΩ or more?

Go to step 3.

Repair the short circuit of harness between TCM connector and transmission connector.

Is “OFF” displayed?

Go to step 4.

Go to step 6.

Is “ON” displayed?

Check for poor Go to step 5. contact of harness in the solenoid output and oil pressure SW input, and repair the fault location.

5AT(diag)-75

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5

6

Step Check CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 9 — (T10) No. 10: (T4) No. 13 — (T11) No. 7: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or TRANSMISSION AND CONTROL VALVE more? BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T10) No. 10 — Transmission ground:

5AT(diag)-76

Yes Replace the control valve body.

No Replace the transmission harness assembly.

Replace the control valve body.

Repair the short circuit of harness between transmission connector and control valve body connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Z: DTC P0773 SHIFT SOLENOID “E” ELECTRICAL DTC DETECTING CONDITION: Output signal circuit of forward brake solenoid is open or shorted. TROUBLE SYMPTOM: Locked to 2nd, 3rd or 4th gear. WIRING DIAGRAM: B11

T11

13

B55

TCM

T11

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

A:

B11

B54

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

T4

7

1 2 3 4 5 6 7 8

A22

B:

A23

B54

B19

A:

B:

E

B55

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

FORWARD BRAKE LINEAR SOLENOID CONTROL VALVE BODY

5 6 14 15 16 25 26 27 33 34 35

AT-05325

1

2

Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 19 — (B11) No. 13: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or Go to step 3. TCM AND BODY HARNESS. more? Measure the resistance of harness between TCM connector and body harness. Connector & terminal (B55) No. 19 — Chassis ground:

5AT(diag)-77

No Repair the open circuit of harness between TCM connector and transmission connector.

Repair the short circuit of harness between TCM connector and transmission connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3

4

5

6

7

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 13 — (T11) No. 7: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 7 — Transmission ground: CHECK FORWARD BRAKE SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 7 — Transmission ground: CHECK FOR POOR CONTACT. Check the TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while and read DTC.

Check Yes Is the resistance less than 1 Ω? Go to step 4.

No Repair the open circuit of harness between transmission connector and control valve body connector.

Is the resistance 1 MΩ or more?

Repair the open circuit of harness between control valve body connector and transmission ground.

Go to step 5.

Is the resistance 5 — 17 Ω?

Go to step 6.

Replace the control valve body.

Go to step 7.

Is there poor contact, loosing Repair the poor terminal, entering foreign mat- contact. ter, or damaging connector body? Is DTC displayed? Replace the TCM.

5AT(diag)-78

Temporary poor contact or open circuit occurs. Recheck that the harness connector has no faulty.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AA:DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT DTC DETECTING CONDITION: Shift lock solenoid malfunction, open or short reverse inhibitor control circuit TROUBLE SYMPTOM: • Gear is shifted from “N” range to “R” range during driving at 20 km/h (12 MPH) or more. • Gear cannot be shifted from “N” range to “R” range though the vehicle is parked. WIRING DIAGRAM:

B116

5

B281 BODY INTEGRATED UNIT

1 2 3 4 5 6 7 8

SHIFT LOCK SOLENOID

B116 3 4

B281 1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

AT-05326

1

2

3

Step CHECK SHIFT LOCK SOLENOID. 1) Forcibly activate the body integrated unit to check the operation of shift lock solenoid. 2) Move the shift lever without depressing the brake pedal. CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT. 1) Display the following items using Subaru Select Monitor. • Key warning SW • Shift position • PSW • Stop light switch 2) With the brake pedal depressed, shift the select lever to “P” range. CHECK HARNESS CONNECTOR BETWEEN BODY INTEGRATED UNIT AND SHIFT LOCK SOLENOID. Measure the harness resistance between the body integrated unit and chassis ground. Connector & terminal (B281) No. 5 — Chassis ground:

Check Does the shift lever move?

Yes Go to step 2.

No Go to step 3.

Do the units of measure of items displayed change?

Go to step 3.

Check the circuits of the items whose values do not change.

Is the resistance 1 MΩ or more?

Go to step 4.

Repair the short circuit of harness between body integrated unit and shift lock solenoid connector.

5AT(diag)-79

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4

5

6

7

8

Step CHECK HARNESS BETWEEN SHIFT LOCK SOLENOID AND CHASSIS GROUND TERMINAL. Measure the resistance of harness between shift lock solenoid connector and chassis ground. Connector & terminal (B116) No. 4 — Chassis ground: CHECK SHIFT LOCK SOLENOID. Measure the resistance between the shift lock solenoid connector terminals. Connector & terminal (B116) No. 3 — No. 4: CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT. 1) Connect all connectors. 2) Turn the ignition switch to ON. 3) Set the select lever to the “D” range. 4) Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B281) No. 5 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT. 1) Lift up the vehicle. 2) Start the engine. 3) Shift the select lever to “D” range and slowly increase vehicle speed to over 20 km/h (12 MPH). NOTE: The speed difference between front and rear wheels lights the ABS warning light or the VDC warning light, but this does not indicate a malfunction. If the warning light illuminates, delete the ABS or VDC memory after completing the AT control diagnosis. 4) Measure the voltage between body integrated unit and chassis ground. Connector & terminal (B281) No. 5 (+) — Chassis ground (–): CHECK FOR POOR CONTACT.

Check Yes Is the resistance less than 1 Ω? Go to step 5.

No Repair the open circuit of the harness between shift lock solenoid connector and chassis ground.

Is the resistance 12 — 18 Ω?

Replace the shift lock solenoid.

Go to step 6.

Is the voltage 10.5 V or more? Go to step 7.

Is the voltage less than 1 V?

Check for poor Go to step 8. contact of the reverse inhibitor control circuit harness or connectors, and repair the fault location.

Repair the poor Is there poor contact of the reverse inhibitor control circuit? contact.

5AT(diag)-80

Go to step 8.

Replace the body integrated unit.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AB:DTC P0817 STARTER DISABLE CIRCUIT DTC DETECTING CONDITION: Open or short in P/N signal output circuit TROUBLE SYMPTOM: • Engine can be started on other than “P” or “N” range. • Engine can not be started on “P” or “N” range. WIRING DIAGRAM:

TO POWER SUPPLY CIRCUIT B136

ST-1 F/B FUSE NO. 21 (ST)

B498

35

ECM

4

2

1 2 3 4

INHIBITOR RELAY B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

3

1

B498

B136

STARTER SYSTEM 5 6 14 15 16 25 26 27 33 34 35

11

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

B54

TCM

AT-05569

1

Step CHECK DTC OF TCM.

2

CHECK ECM.

3

CHECK FUSE (NO. 21). 1) Turn the ignition switch to OFF. 2) Remove the fuse.

Check Is DTC of Transmission Range Sensor Circuit (PRNDL Input) detected? Is the communication between Subaru Select Monitor and ECM normal? Is the fuse (No. 21) blown out?

5AT(diag)-81

Yes No Perform the diag- Go to step 2. nosis according to DTC. Go to step 3. Perform the diagnosis according to DTC of ECM. Replace the fuse Go to step 4. (No. 21). If the replaced fuse (No. 21) has blown out easily, repair the short circuit of harness between fuse (No. 21) and inhibitor relay.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4

5

6

7

8

9

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM, ECM and inhibitor relay. 3) Measure the resistance of harness between TCM connector and ECM connector. Connector & terminal (B54) No. 11 — (B136) No. 35: CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR RELAY. Measure the resistance of the harness between TCM connector and inhibitor relay. Connector & terminal (B54) No. 11 — (B498) No. 1: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 11 — Chassis ground: CHECK OUTPUT SIGNAL OF TCM. 1) Connect the TCM, ECM, and inhibitor relay connector. 2) Turn the ignition switch to ON. 3) Shift the select lever to “P” range. 4) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 11 (+) — Chassis ground (–): CHECK OUTPUT SIGNAL OF TCM. 1) Set the select lever to the “D” range. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 11 (+) — Chassis ground (–): CHECK FOR POOR CONTACT.

Check Yes Is the resistance less than 1 Ω? Go to step 5.

No Repair the open circuit of harness or poor contact of connector between TCM connector and ECM connector.

Is the resistance less than 1 Ω? Go to step 6.

Repair the open circuit of harness or poor contact of connector between TCM connector and inhibitor relay. Repair the short circuit of harness between TCM connector and chassis ground.

Is the resistance 1 MΩ or more?

Go to step 7.

Is the voltage 1 V or less?

Go to step 8.

Replace the TCM.

Is the voltage 8 V or more?

Go to step 9.

Replace the TCM.

Is there any open or poor con- Repair the poor tact of connector (loosing termi- contact. nal, entering foreign matter, damaging connector body)?

5AT(diag)-82

Check the neutral switch of ECM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AC:DTC P0957 BACKUP LIGHT RELAY CIRCUIT LOW DTC DETECTING CONDITION: Open or short circuit of back-up light relay output circuit TROUBLE SYMPTOM: Back-up light does not illuminate in “R” range. WIRING DIAGRAM:

TO POWER SUPPLY CIRCUIT

FB-29 F/B FUSE NO. 18 (IG)

1 2 3 4

4

2

B499

BACK-UP LIGHT RELAY

B499

3

1

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

13

BACK-UP LIGHT SYSTEM

B54 TCM

AT-05570

1

2

3

Step CHECK DTC OF TCM.

Check Is DTC of Transmission Range Sensor Circuit (PRNDL Input) detected? CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? TCM AND BACK-UP LIGHT RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM and back-up light relay. 3) Measure the resistance of harness between TCM connector and back-up light relay connector. Connector & terminal (B54) No. 13 — (B499) No. 1: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or more? TCM AND TRANSMISSION. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 13 — Chassis ground:

5AT(diag)-83

Yes No Perform the diag- Go to step 2. nosis according to DTC. Go to step 3. Repair the open circuit of harness or poor contact of connector between TCM connector and transmission connector.

Go to step 4.

Repair the short circuit of harness between TCM connector and transmission connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4

5

6

Step Check CHECK OUTPUT SIGNAL OF TCM. Is the voltage 8 V or more? 1) Turn the ignition switch to ON. 2) Shift the select lever to “P” range. 3) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 13 (+) — Chassis ground (–): Is the voltage 1 V or less? CHECK OUTPUT SIGNAL OF TCM. 1) Set the select lever to “R” range. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 13 (+) — Chassis ground (–): CHECK INPUT VOLTAGE FOR BACK-UP Is the voltage 10 — 13 V? LIGHT RELAY. Measure the voltage between back-up light relay and chassis ground.

5AT(diag)-84

Yes Go to step 5.

No Replace the TCM.

Go to step 6.

Replace the TCM.

Replace the back- Check open or up light relay. short circuit of harness between fuse (No. 18) and backup light relay.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AD:DTC P0958 BACKUP LIGHT RELAY CIRCUIT HIGH DTC DETECTING CONDITION: Open or short circuit of back-up light relay output circuit TROUBLE SYMPTOM: Back-up light does not illuminate in “R” range. WIRING DIAGRAM:

TO POWER SUPPLY CIRCUIT

FB-29 F/B FUSE NO. 18 (IG)

1 2 3 4

4

2

B499

BACK-UP LIGHT RELAY

B499

3

1

B54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 20 21 22 23 26 27 28 29 30 31 32 33 34 35

13

BACK-UP LIGHT SYSTEM

B54 TCM

AT-05570

1

2

3

Step CHECK DTC OF TCM.

Check Is DTC of Transmission Range Sensor Circuit (PRNDL Input) detected? CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? TCM AND BACK-UP LIGHT RELAY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from TCM and back-up light relay. 3) Measure the resistance of harness between TCM connector and back-up light relay connector. Connector & terminal (B54) No. 13 — (B499) No. 1: CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or more? TCM AND TRANSMISSION. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 13 — Chassis ground:

5AT(diag)-85

Yes No Perform the diag- Go to step 2. nosis according to DTC. Go to step 3. Repair the open circuit of harness or poor contact of connector between TCM connector and back-up light relay connector.

Go to step 4.

Repair the short circuit of harness between TCM connector and transmission connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4

5

6

Step Check CHECK OUTPUT SIGNAL OF TCM. Is the voltage 8 V or more? 1) Turn the ignition switch to ON. 2) Shift the select lever to “P” range. 3) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 13 (+) — Chassis ground (–): Is the voltage 1 V or less? CHECK OUTPUT SIGNAL OF TCM. 1) Set the select lever to “R” range. 2) Measure the voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 13 (+) — Chassis ground (–): CHECK INPUT VOLTAGE FOR BACK-UP Is the voltage 10 — 13 V? LIGHT RELAY. Measure the voltage between back-up light relay and chassis ground.

5AT(diag)-86

Yes Go to step 5.

No Replace the TCM.

Go to step 6.

Replace the TCM.

Replace the back- Check open or up light relay. short circuit of harness between fuse (No. 18) and backup light relay.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AE:DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR WHEEL) DTC DETECTING CONDITION: Input signal circuit of TCM is open or shorted. TROUBLE SYMPTOM: Shifting quality malfunction WIRING DIAGRAM: AT4

TCM 1

2

1 2 3 4 5 6 7 8

3

23

16 27

B55

B12

B11

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 1 2

B12

5

5

2 7

B11 T4

T3

1 3 2

B55 1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

AT4 REAR VEHICLE SPEED SENSOR

1

2

3

5 6 14 15 16 25 26 27 33 34 35

AT-05329

Step CHECK TCM I/O SIGNAL. Check I/O signal of power supply and ground.

CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. 1) Disconnect the connectors from TCM and transmission. 2) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 16 — (B11) No. 2: (B55) No. 23 — (B12) No. 5: (B55) No. 27 — (B11) No. 7: CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 16 — Chassis ground: (B55) No. 23 — Chassis ground: (B55) No. 27 — Chassis ground:

Check Is TCM I/O signal OK?

Yes Go to step 2.

No Repair the open or short circuit for power supply and ground.

Is the resistance less than 1 Ω? Go to step 3.

Repair the open circuit of harness between TCM connector and transmission connector.

Go to step 4.

Repair the short circuit of harness between TCM connector and transmission connector.

Is the resistance 1 MΩ or more?

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4

5

6

7

Step CHECK TCM POWER SUPPLY OUTPUT. 1) Connect the connector to TCM. (Transmission connector is disconnected) 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B11) No. 7 (+) — Chassis ground (–): CHECK TURBINE SPEED SENSOR FOR TCM. Measure the voltage change between TCM connector terminals. Connector & terminal (B12) No. 5 (+) — (B11) No. 2 (–): CHECK HARNESS ASSEMBLY (TURBINE SPEED SENSOR GROUND). Check the installing condition of ground connecting harness (used for both of turbine speed sensor 1, rear vehicle speed sensor).

Check Is the voltage 10 — 13 V?

Yes Go to step 5.

No Replace the TCM.

Is the voltage 4 — 6 V?

Go to step 7.

Go to step 6.

Is the ground connecting harness installed to transmission body correctly, or the harness and connector terminals not damaged?

Go to step 7.

When the poor installation of ground connecting harness, install it securely. Replace the transmission assembly when the harness is damaged. CHECK INPUT SIGNAL FOR TCM. Does the speedometer indica- Check for poor Replace the trans1) Connect all connectors. tion in the combination meter contact of the ATF mission harness. 2) Lift up the vehicle. temperature senchange according to “Rear 3) Start the engine. sor and transmisWheel Speed” data? 4) Read the data of “Rear Wheel Speed” using sion connector Subaru Select Monitor. repair the fault location. NOTE: The speed difference between front and rear wheels lights the ABS warning light or the VDC warning light, but this does not indicate a malfunction. If the warning light illuminates, delete the ABS or VDC memory after completing the AT control diagnosis.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AF:DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION DTC DETECTING CONDITION: Output signal circuit of transfer solenoid is open or shorted. TROUBLE SYMPTOM: • Tight corner braking phenomenon occurs. • Drivability getting worse. WIRING DIAGRAM: T11 1 2 3 4 5 6 7 8

TCM

B55

A22

B:

A23

B54

B2

A:

B11

1 2

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18 5

B54

8

B11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 24 25 28 29 30 31 32 33 34 35

6

T4

B55

T11

TRANSFER LINEAR SOLENOID

E

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

CONTROL VALVE BODY

1

2

5 6 14 15 16 25 26 27 33 34 35

AT-05330

Step Check Yes CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Ω? Go to step 2. TCM AND TRANSMISSION. 1) Turn the ignition switch to OFF. 2) Disconnect the connectors from TCM and transmission. 3) Measure the resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 22 — Chassis ground: (B54) No. 23 — Chassis ground: (B55) No. 2 — (B11) No. 8: Go to step 3. CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 MΩ or more? TCM AND CHASSIS GROUND. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 23 — Chassis ground:

5AT(diag)-89

No Repair the open circuit of harness between TCM connector and transmission connector.

Repair the short circuit of harness between TCM connector and transmission connector.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3

4

5

6

7

Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T4) No. 8 — (T11) No. 6: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 6 — Transmission ground: CHECK TRANSFER SOLENOID. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T11) No. 6 — Transmission ground: CHECK FOR POOR CONTACT. Check the TCM connector, transmission connector and control valve body connector. CHECK AFTER REPAIR. 1) Perform the Clear Memory Mode. 2) Drive for a while and read DTC.

Check Yes Is the resistance less than 1 Ω? Go to step 4.

No Repair the open circuit of harness between transmission connector and control valve body connector.

Is the resistance 1 MΩ or more?

Repair the open circuit of harness between control valve body connector and transmission ground.

Go to step 5.

Is the resistance 3 — 9 Ω?

Go to step 6.

Replace the control valve body.

Go to step 7.

Is there poor contact, loosing Repair the poor terminal, entering foreign mat- contact. ter, or damaging connector body? Is DTC displayed? Replace the TCM.

5AT(diag)-90

Temporary poor contact or open circuit occurs. Recheck that the harness connector has no faulty.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AG:DTC P1710 TORQUE CONVERTER TURBINE 2 SPEED SIGNAL CIRCUIT MALFUNCTION DTC DETECTING CONDITION: Input signal circuit of TCM is open or shorted. TROUBLE SYMPTOM: • Excessive shift shock • Does not shift to 5th. WIRING DIAGRAM: 1 2 3 4 5 6

1 2 3 4 5 6 7 8

T10

B12

1 2 3 4 5 6 7 8 9 10

T3

B11

T10

3 4 6 7 8 9 10 11 12 13 14 15 16 19 20 17 18

6

7

B11 2

B12

25

TCM

27

16

B55

T14

T4

1 2

1

1

T14

4

5

B55

TURBINE SPEED SENSOR 2

1 2 3 4 7 8 9 10 11 12 13 17 18 19 20 21 22 23 24 28 29 30 31 32

CONTROL VALVE BODY

1

2

3

4

5 6 14 15 16 25 26 27 33 34 35

AT-05331

Step CHECK TCM I/O SIGNAL. Check I/O signal of power supply and ground.

CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. 1) Disconnect the connectors from TCM and transmission. 2) Measure the resistance of harness between TCM connector and transmission connector. Connector & terminal (B55) No. 16 — (B11) No. 2: (B55) No. 25 — (B12) No. 6: (B55) No. 27 — (B11) No. 7: CHECK TCM AND TRANSMISSION HARNESS CONNECTOR. Measure the resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 25 — Chassis ground: CHECK TCM POWER SUPPLY OUTPUT. 1) Connect the connector to TCM. (Transmission connector is disconnected) 2) Turn the ignition switch to ON. 3) Measure the voltage between transmission connector and chassis ground. Connector & terminal (B11) No. 7 (+) — Chassis ground (–):

Check Is TCM I/O signal OK?

Yes Go to step 2.

No Repair the open or short circuit for power supply and ground.

Is the resistance less than 1 Ω? Go to step 3.

Repair the open circuit of harness between TCM connector and transmission connector.

Is the resistance 1 MΩ or more?

Go to step 4.

Repair the short circuit of harness between TCM connector and transmission connector.

Is the voltage 10 — 13 V?

Go to step 5.

Replace the TCM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5

6

7

8

Step CHECK TURBINE SPEED SENSOR 2 INPUT CIRCUIT FOR TCM. Measure the voltage between TCM connector terminals. Connector & terminal (B12) No. 6 (+) — (B11) No. 2 (–): CHECK INPUT SIGNAL FOR TCM. 1) Connect all connectors. 2) Lift up the vehicle. 3) Start the engine. 4) Drive at 1st of manual mode. 5) Using Subaru Select Monitor, read the data of “AT Turbine Speed 2”. NOTE: The speed difference between front and rear wheels lights the ABS warning light or the VDC warning light, but this does not indicate a malfunction. If the warning light illuminates, delete the ABS or VDC memory after completing the AT control diagnosis. CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from transmission. 3) Remove the transmission connector from bracket. 4) Lift up the vehicle. 5) Drain the ATF. CAUTION: Do not drain ATF until it cools down. 6) Remove the oil pan. 7) Disconnect the control valve body connector. 8) Measure the resistance between transmission connector and control valve body connector. Connector & terminal (T3) No. 6 — (T10) No. 1: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND CONTROL VALVE BODY. Measure the resistance between transmission ground and control valve body connector. Connector & terminal (T10) No. 1 — Transmission ground:

Check Is the voltage 4 — 6 V?

Yes Go to step 6.

No Replace the TCM.

Does the speedometer indication in the combination meter change according to “AT Turbine Speed 2” data?

Check for poor Go to step 7. contact of the turbine speed sensor 2 and transmission connector harness, and repair the fault location.

Is the resistance less than 1 Ω? Go to step 8.

Repair the open circuit of harness between transmission connector and control valve body connector.

Is the resistance 1 MΩ or more?

Repair the short circuit of harness between control valve body connector and transmission ground.

Replace the control valve body.

AH:DTC P1718 AT CAN COMMUNICATION CIRCUIT NOTE: For DTC P1718 AT CAN communication circuit, refer to “LAN System”.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AI: DTC P1724 AT EEPROM ERROR DTC DETECTING CONDITION: TCM EEPROM malfunction TROUBLE SYMPTOM: • AT learning is not finished. • Shock occurs when selecting N → D, N → R. 1

2

Step CHECK BATTERY. 1) Turn the ignition switch to ON. 2) Read the data of “Battery voltage” using Subaru Select Monitor. CHECK DTC. 1) Turn the ignition switch to OFF. 2) Turn the ignition switch to ON after one minute.

Check Yes Is the “Battery voltage” 10 V or Go to step 2. more?

No Check the battery.

Is DTC P1724 displayed as a temporary code?

Current condition is normal. Check for poor contact of TCM connector or harness.

5AT(diag)-93

Replace the TCM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AJ:DTC P1817 SPORTS MODE SWITCH CIRCUIT (MANUAL SWITCH) DTC DETECTING CONDITION: Input signal circuit of manual mode switch is open or shorted. TROUBLE SYMPTOM: • Manual mode can not be set. • Shift indicator light displays when “N” → “D” is selected. WIRING DIAGRAM:

B 54

TCM

6

B116

7

1 2 3 4 5 6 7 8

SELECT LEVER

MANUAL MODE SWITCH

B 54

B116

8

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31

4 5 6 7 14 15 16 17 18 19 24 25 26 27 32 33 34 35

E AT-05332

1

2

3

4

Step CHECK GROUND CIRCUIT OF MANUAL MODE SWITCH. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from manual mode switch. 3) Measure the resistance of harness between manual mode switch connector and chassis ground. Connector & terminal (B116) No. 8 — Chassis ground: CHECK MANUAL MODE SWITCH. Measure the resistance between manual mode switch terminals. Connector & terminal (B116) No. 7 — No. 8: CHECK MANUAL MODE SWITCH. 1) Shift the select lever to manual mode. 2) Measure the resistance between manual mode switch terminals. Connector & terminal (B116) No. 7 — No. 8: CHECK HARNESS CONNECTOR BETWEEN TCM AND MANUAL MODE SWITCH. 1) Disconnect the connector from TCM. 2) Measure the resistance of harness between TCM connector and manual mode switch connector. Connector & terminal (B116) No. 7 — (B54) No. 6:

Check Yes Is the resistance less than 1 Ω? Go to step 2.

No Repair the open circuit of harness between manual mode switch and chassis ground.

Go to step 3.

Replace the select lever assembly.

Is the resistance less than 1 Ω? Go to step 4.

Replace the select lever assembly.

Is the resistance less than 1 Ω? Go to step 5.

Repair the open circuit of harness or poor contact of connector between manual mode switch connector and TCM connector.

Is the resistance 1 MΩ or more?

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5

6

7

Step CHECK HARNESS CONNECTOR BETWEEN TCM AND MANUAL MODE SWITCH. 1) Disconnect the connector from TCM. 2) Measure the resistance of harness between manual mode switch connector and chassis ground. Connector & terminal (B116) No. 7 — Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect the connector to TCM and manual mode switch. 2) Turn the ignition switch to ON. 3) Shift the select lever to the normal mode. 4) Measure the voltage of signal to TCM. Connector & terminal (B54) No. 6 (+) — Chassis ground (–): CHECK FOR POOR CONTACT.

Check Is the resistance 1 MΩ or more?

Yes Go to step 6.

No Repair the short circuit of harness between manual mode switch connector and TCM connector.

Is the voltage 10 V or more?

Go to step 7.

Replace the TCM.

Is there poor contact of the manual mode switch circuit?

Repair the poor contact.

Replace the TCM.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AK:DTC P1840 TRANSMISSION FLUID PRESSURE SENSOR SWITCH A CIRCUIT DTC DETECTING CONDITION: Front brake oil pressure switch malfunction TROUBLE SYMPTOM: Excessive shift shock NOTE: Refer to DTC P0751 for diagnostic procedure.

AL:DTC P1841 TRANSMISSION FLUID PRESSURE SENSOR SWITCH B CIRCUIT DTC DETECTING CONDITION: Forward brake oil pressure switch malfunction. TROUBLE SYMPTOM: Excessive shift shock NOTE: Refer to DTC P0771 for diagnostic procedure.

AM:DTC P1842 TRANSMISSION FLUID PRESSURE SENSOR SWITCH C CIRCUIT DTC DETECTING CONDITION: Input clutch oil pressure switch is malfunction. TROUBLE SYMPTOM: Excessive shift shock NOTE: Refer to DTC P0756 for diagnostic procedure.

AN:DTC P1843 TRANSMISSION FLUID PRESSURE SENSOR SWITCH D CIRCUIT DTC DETECTING CONDITION: Direct clutch oil pressure switch malfunction. TROUBLE SYMPTOM: Excessive shift shock NOTE: Refer to DTC P0766 for diagnostic procedure.

AO:DTC P1844 TRANSMISSION FLUID PRESSURE SENSOR SWITCH E CIRCUIT DTC DETECTING CONDITION: High & low reverse clutch oil pressure switch malfunction. TROUBLE SYMPTOM: Excessive shift shock NOTE: Refer to DTC P0761 for diagnostic procedure.

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Diagnostic Procedure without Diagnostic Trouble Code (DTC) AUTOMATIC TRANSMISSION (DIAGNOSTICS)

17.Diagnostic Procedure without Diagnostic Trouble Code (DTC) A: CHECK SHIFT INDICATOR DIAGNOSIS: • Output signal circuit of shift indicator is open or shorted. • Combination meter malfunction TROUBLE SYMPTOM: • Shift indicator does not display or remains displayed. • Shift indicator display does not change. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT

FB-30 F/B FUSE NO. 5 (IG)

B54

19

1 2 3 8 9 10 11 12 13 20 21 22 23 28 29 30 31 LCD SHIFT INDICATOR · SHIFT UP · SHIFT DOWN · SHIFT POSITION

I/F

4 5 6 7 14 15 16 17 18 19 26 27 24 25 34 35 32 33

COMBINATION METER

i10 MICRO COMPUTER

20

32

21

33

CAN TRANSCEIVER & RECEIVER

B54

TCM

i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

AT-05333

1

2

3

4

Step Check CHECK TCM. Is DTC displayed? Check the DTC relating the TCM using the Subaru Select Monitor. CHECK COMBINATION METER. Is DTC displayed? Check the DTC of combination meter. CHECK TCM. Is the gear position “1”? 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON. 4) Run the Subaru Select Monitor. 5) Shift the select lever to manual mode. 6) Read the data of “Gear Position” using Subaru Select Monitor. CHECK TCM. Is the gear position “2”? 1) Shift up the select lever. 2) Read the data of “Gear Position” using Subaru Select Monitor.

5AT(diag)-97

Yes No Perform the diag- Go to step 2. nosis according to DTC. Perform the diag- Go to step 3. nosis according to DTC. Go to step 4. Replace the TCM.

Replace the combination meter assembly.

Replace the TCM.

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION (DIAGNOSTICS)

18.Diagnostics with Phenomenon A: INSPECTION Symptoms

Shifting vehicle speed is low on “D” range.

Shifting vehicle speed is high on “D” range.

Excessive shifting shock. (“N” → “D” range)

Excessive shift shock on 1st of “D” range → 2nd of “D” range or “1st of manual mode” → “2nd of manual mode”.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Problem parts Vehicle speed sensor 1 and vehicle speed sensor 2 Accelerator pedal position sensor Throttle position sensor ATF temperature sensor CAN communication signal Vehicle speed sensor 1 and vehicle speed sensor 2 Accelerator pedal position sensor Throttle position sensor CAN communication signal Brake switch signal ATF temperature sensor Engine idle speed Engine speed signal Accelerator pedal position sensor Throttle position sensor Control cable adjustment ATF temperature sensor Oil pressure switch 1 and front brake solenoid valve CAN communication signal Fluid level and condition TCM power supply Accelerator pedal position sensor Throttle position sensor Control cable adjustment Oil pressure switch 4 and direct clutch solenoid valve CAN communication signal Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition

Excessive shift shock on 2nd of “D” range → 3rd of “D” range or “2nd gear of manual mode” → “3rd of manual mode”.

• Accelerator pedal position sensor • Throttle position sensor • Control cable adjustment • Oil pressure switch 5 and high & low reverse clutch solenoid valve • CAN communication signal • Engine speed signal • Turbine speed sensor 1 and turbine speed sensor 2 • Vehicle speed sensor 1 and vehicle speed sensor 2 • Fluid level and condition

Excessive shift shock on 3rd of “D” range → 4th of “D” range or “3rd of manual mode” → “4th of manual mode”.

• • • • • • • • •

Accelerator pedal position sensor Throttle position sensor Control cable adjustment Oil pressure switch 3 and input clutch solenoid valve CAN communication signal Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION (DIAGNOSTICS) Symptoms

Excessive shift shock on 4th of “D” range → 5th of “D” range or “4th of manual mode” → “5th of manual mode”.

Excessive shock at kick down.

Excessive shock at shift up.

Excessive shock at lock up.

Excessive shock at engine brake.

Judder occurs at lock up.

Noise at “R”, “N” and “D” range.

Hold at “D” range or 1st on manual mode.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Problem parts Accelerator pedal position sensor Throttle position sensor Control cable adjustment Oil pressure switch 1 and front brake solenoid valve CAN communication signal Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition Accelerator pedal position sensor Throttle position sensor Control cable adjustment CAN communication signal Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition Accelerator pedal position sensor Throttle position sensor Control cable adjustment Engine speed signal CAN communication signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition Accelerator pedal position sensor Throttle position sensor Control cable adjustment Engine speed signal CAN communication signal Turbine speed sensor 1 and turbine speed sensor 2 Lock up solenoid valve Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition Accelerator pedal position sensor Throttle position sensor Control cable adjustment CAN communication signal Fluid level and condition Line pressure Forward brake solenoid valve Fluid level and condition Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Vehicle speed sensor 1 and vehicle speed sensor 2 Accelerator pedal position sensor Throttle position sensor Lock up solenoid valve ATF temperature sensor Fluid level and condition Engine speed signal ATF temperature sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Direct clutch solenoid valve Line pressure Up switch signal CAN communication signal Accelerator pedal position sensor

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION (DIAGNOSTICS) Symptoms

Problem parts • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Forward brake solenoid valve • Line pressure • Up switch signal • Down switch signal • CAN communication signal • Accelerator pedal position sensor • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Line pressure • Up switch signal • Down switch signal • CAN communication signal • Accelerator pedal position sensor • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 3 and input clutch solenoid valve • Oil pressure switch 4 and direct clutch solenoid valve • Oil pressure switch 5 and high & low reverse clutch solenoid valve • Forward brake solenoid valve • Front brake solenoid valve • Line pressure • Up switch signal • Down switch signal • CAN communication signal • Accelerator pedal position sensor • TCM power supply • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 1 and front brake solenoid valve • Line pressure • Down switch signal • CAN communication signal • Accelerator pedal position sensor

Hold at “D” range or 2nd on manual mode.

Hold at “D” range or 3rd on manual mode.

Hold at “D” range or 4th on manual mode.

Hold at “D” range or 5th on manual mode.

Gear does not shift 1st of “D” range → 2nd of “D” range or “1st of manual mode” → “2nd of manual mode”.

Gear does not shift 2nd of “D” range → 3rd of “D” range or “2nd of manual mode” → “3rd of manual mode”.

Gear does not shift 3rd of “D” range → 4th of “D” range or “3rd of manual mode” → “4th of manual mode”.

• Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 4 and direct clutch solenoid valve • Line pressure • Up switch signal • CAN communication signal • Accelerator pedal position sensor • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 5 and high & low reverse clutch solenoid valve • Line pressure • Up switch signal • CAN communication signal • Accelerator pedal position sensor • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 3 and input clutch solenoid valve • Oil pressure switch 1 and front brake solenoid valve • Line pressure • Up switch signal • CAN communication signal • Accelerator pedal position sensor

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION (DIAGNOSTICS) Symptoms

Gear does not shift 4th of “D” range → 5th of “D” range or “4th of manual mode” → “5th of manual mode”.

Gear does not shift down to 4th on “D” range or manual mode.

Gear does not shift down to 3rd on “D” range or manual mode.

Gear does not shift down to 2nd on “D” range or manual mode.

Gear does not shift down to 1st on “D” range or manual mode.

No lock-up occurs.

No shifting shock occurred when shifting 1st of “D” range → 2nd of “D” range or “1st of manual mode” → “2nd of manual mode”. Or clutch slipping occurred.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Problem parts Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 1 and front brake solenoid valve Oil pressure switch 4 and direct clutch solenoid valve Turbine speed sensor 1 and turbine speed sensor 2 ATF temperature sensor Line pressure Up switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 1 and front brake solenoid valve Oil pressure switch 4 and direct clutch solenoid valve Line pressure Down switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 3 and input clutch solenoid valve Oil pressure switch 1 and front brake solenoid valve Line pressure Down switch signal CAN communication signal Accelerator pedal position sensor TCM power supply Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 5 and high & low reverse clutch solenoid Line pressure Down switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 4 and direct clutch solenoid valve Line pressure Down switch signal CAN communication signal Accelerator pedal position sensor Fluid level and condition Line pressure Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Lock up solenoid valve CAN communication signal ATF temperature sensor Accelerator pedal position sensor Brake switch signal Range signal

• • • • •

Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 4 and direct clutch solenoid valve Line pressure CAN communication signal

5AT(diag)-101

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION (DIAGNOSTICS) Symptoms No shifting shock occurred when shifting 2nd of “D” range → 3rd of “D” range or “2nd of manual mode” → “3rd of manual mode”. Or clutch slipping occurred.

No shifting shock occurred when shifting 3rd of “D” range → 4th of “D” range or “3rd of manual mode” → “4th of manual mode”. Or clutch slipping occurred.

No shifting shock occurred when shifting 4th of “D” range → 5th of “D” range or “4th of manual mode” → “5th of manual mode”. Or clutch slipping occurred.

Engine skids when shifting 5th of “D” range → 4th of “D” range or “5th of manual mode” → “4th of manual mode”. Or slipping occurred.

Engine skids when shifting 4th of “D” range → 3rd of “D” range or “4th of manual mode” → “3rd of manual mode”. Or slipping occurred.

Engine skids when shifting 3rd of “D” range → 2nd of “D” range or “3rd of manual mode” → “2nd of manual mode”. Or slipping occurred.

Engine skids when shifting 2nd of “D” range → 1st of “D” range or “2nd of manual mode” → “1st of manual mode”. Or slipping occurred.

Engine brake does not function at 5th → 4th of manual mode.

Engine brake does not function at 4th → 3rd of manual mode.

Problem parts • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 5 and high & low reverse clutch solenoid valve • Line pressure • CAN communication signal • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 3 and input clutch solenoid valve • Oil pressure switch 1 and front brake solenoid valve • Line pressure • CAN communication signal • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 1 and front brake solenoid valve • Oil pressure switch 4 and direct clutch solenoid valve • Line pressure • Accelerator pedal position sensor • Throttle position sensor • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 1 and front brake solenoid valve • Oil pressure switch 4 and direct clutch solenoid valve • Line pressure • Accelerator pedal position sensor • Throttle position sensor • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 3 and input clutch solenoid valve • Oil pressure switch 1 and front brake solenoid valve • Line pressure • Accelerator pedal position sensor • Throttle position sensor • Fluid level and condition • Vehicle speed sensor 1 and vehicle speed sensor 2 • Oil pressure switch 5 and high & low reverse clutch solenoid valve • Oil pressure switch 4 and direct clutch solenoid valve • Line pressure • Accelerator pedal position sensor • Throttle position sensor • • • • • • • • • • • • • • • • • •

Fluid level and condition Vehicle speed sensor 1 and vehicle speed sensor 2 Oil pressure switch 4 and direct clutch solenoid valve Line pressure Accelerator pedal position sensor Throttle position sensor Inhibitor switch Fluid level and condition Control cable adjustment Manual mode switch Oil pressure switch 1 Down switch signal Inhibitor switch Fluid level and condition Control cable adjustment Manual mode switch Oil pressure switch 1 and oil pressure switch 3 Down switch signal

5AT(diag)-102

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION (DIAGNOSTICS) Symptoms

Engine brake does not function at 3rd → 2nd of manual mode.

Engine brake does not function at 2nd → 1st of manual mode.

Excessive acceleration failure on “D” range.

Excessive acceleration failure in “R” range.

Engine skids when start driving (1st) the vehicle. Or slipping occurred.

Engine skids when driving at 2nd. Or slipping occurred.

Engine skids when driving at 3rd. Or slipping occurred.

Engine skids when driving at 4th. Or slipping occurred.

Problem parts • Inhibitor switch • Fluid level and condition • Control cable adjustment • Manual mode switch • Oil pressure switch 5 • Forward brake solenoid valve • Inhibitor switch • Fluid level and condition • Control cable adjustment • Manual mode switch • Oil pressure switch 4 • Forward brake solenoid valve • Fluid level and condition • Line pressure • Accelerator pedal position sensor • Throttle position sensor • CAN communication signal • Inhibitor switch • Control cable adjustment • Vehicle speed sensor 1 and vehicle speed sensor 2 • Fluid level and condition • Line pressure • Accelerator pedal position sensor • Throttle position sensor • Oil pressure switch 5 and high & low reverse clutch solenoid valve • CAN communication signal • Inhibitor switch • Control cable adjustment • Vehicle speed sensor 1 and vehicle speed sensor 2 • Fluid level and condition • Line pressure • Accelerator pedal position sensor • Throttle position sensor • CAN communication signal • Fluid level and condition • Line pressure • Accelerator pedal position sensor • Throttle position sensor • CAN communication signal • Oil pressure switch 4 and direct clutch solenoid valve • Fluid level and condition • Line pressure • Accelerator pedal position sensor • Throttle position sensor • CAN communication signal • Oil pressure switch 5 and high & low reverse clutch solenoid valve • Fluid level and condition • Line pressure • Accelerator pedal position sensor • Throttle position sensor • CAN communication signal • Oil pressure switch 3 and input clutch solenoid valve

5AT(diag)-103

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION (DIAGNOSTICS) Symptoms

Engine skids when driving at 5th. Or slipping occurred.

Slip at lock up.

Maximum vehicle speed is low.

There is no creep.

Excessive large creep. Vehicle cannot be parking condition on “P” range. Parking condition is not released though shifting to other ranges. Vehicle can drive on “P” range.

Vehicle can drive on “N” range.

Vehicle cannot drive at any range.

Vehicle cannot drive on “D” range.

Vehicle cannot drive on “R” range.

• • • • • • • • • • • • • • • • • • • • • • • • • • •

Problem parts Fluid level and condition Line pressure Accelerator pedal position sensor Throttle position sensor CAN communication signal Oil pressure switch 1 and front brake solenoid valve Fluid level and condition Line pressure Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Lock up solenoid valve CAN communication signal Fluid level and condition Line pressure Accelerator pedal position sensor Throttle position sensor CAN communication signal Direct clutch solenoid valve Vehicle speed sensor 1 and vehicle speed sensor 2 Fluid level and condition Engine speed signal CAN communication signal Oil pressure switch 4 and direct clutch solenoid valve Line pressure Engine speed signal CAN communication signal Oil pressure switch 4

• • • • • •

Inhibitor switch Control cable adjustment Inhibitor switch Fluid level and condition Control cable adjustment Line pressure

• • • • • • • • • • • • • • • • • • • • • •

Inhibitor switch Fluid level and condition Control cable adjustment Line pressure Fluid level and condition Line pressure Inhibitor switch Control cable adjustment Loosing or damaging of propeller shaft. Loosing or damaging of drive shaft. Fluid level and condition Line pressure Inhibitor switch Control cable adjustment Loosing or damaging of propeller shaft. Loosing or damaging of drive shaft. Fluid level and condition Line pressure Inhibitor switch Control cable adjustment Loosing or damaging of propeller shaft. Loosing or damaging of drive shaft.

5AT(diag)-104

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION (DIAGNOSTICS) Symptoms

Engine cannot start on “N” or “P” range.

Engine starts other than “N” or “P” range.

Engine stalls.

Engine stalls when shifting to “N” → “D” and “R” range.

• • • • • • • • • • • • • • • • • • •

Problem parts Starter Control cable adjustment Inhibitor switch CAN communication line TCM Starter Control cable adjustment Inhibitor switch TCM Fluid level and condition Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Lock up solenoid valve Line pressure Fluid level and condition Engine speed signal Turbine speed sensor 1 and turbine speed sensor 2 Lock up solenoid valve Line pressure

5AT(diag)-105

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Diagnostics with Phenomenon AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5AT(diag)-106

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MANUAL TRANSMISSION AND DIFFERENTIAL

6MT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Page General Description ...................................................................................2 Transmission Gear Oil .............................................................................23 Manual Transmission Assembly ..............................................................24 Transmission Mounting System ...............................................................31 Oil Seal .....................................................................................................33 Differential Side Retainer Oil Seal ............................................................35 Switches and Harness .............................................................................36 Preparation for Overhaul ..........................................................................38 Transfer Case and Extension Case Assembly .........................................39 Transfer Drive Gear .................................................................................45 Transfer Driven Gear ...............................................................................47 Center Differential ....................................................................................49 Shift Link Assembly ..................................................................................50 Transmission Case ..................................................................................55 Main Shaft Assembly for Single-Range ...................................................58 Drive Pinion Shaft Assembly ....................................................................64 Front Differential Assembly ......................................................................73 Reverse Idler Gear ...................................................................................81 Shifter Fork and Rod ................................................................................87 General Diagnostic Table .........................................................................91

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

1. General Description A: SPECIFICATION 1. MANUAL TRANSMISSION AND DIFFERENTIAL Model Type

Transmission gear ratio

Front reduction gear

Final

1st 2nd 3rd 4th 5th 6th Rev. Type of gear Gear ratio

Type of gear Gear ratio Type of gear Final Gear ratio Front differential Type and number of gear Center differential Type and number of gear Transmission gear oil

Rear reduction gear

Transfer

Transmission gear oil capacity

2.5 L non-turbo Except for OUTBACK OUTBACK 6-forward speeds and 1-reverse 3.454 1.947 1.296 0.972 0.825 0.695 3.636 4.111

Hypoid 4.444

2.5 L turbo

0.780 0.666

4.111

Helical 1.000 Hypoid 4.111 4.444 4.111 Straight bevel gear (bevel pinion: 2, bevel gear: 2) Straight bevel gear (Bevel pinion: 2, bevel gear: 2 and viscous coupling) GL-5

Single-range model

3.7 2 (3.9 US qt, 3.3 Imp qt)

2. TRANSMISSION GEAR OIL Recommended oil: GL-5 (75W-90) or equivalent

6MT-2

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

B: COMPONENT 1. TRANSMISSION CASE T1 (9)

(5) (6) (7)

(4)

(8)

(4)

(1) (2) T2

(3)

MT-02048

(1) (2) (3)

Transmission case ASSY Gasket Drain plug

(6) (7) (8)

Harness bracket Oil level gauge Ground cable

(4)

Harness clip

(9)

Select bracket

(5)

Clamp

6MT-3

Tightening torque:N·m (kgf-m, ft-lb) T1: 18 (1.8, 13.3) T2: 44 (4.5, 32.5) (Aluminum gasket silver) 70 (7.1, 51.6) (Copper gasket brown) 70 (7.1, 51.6) (Metal gasket black)

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

Transmission case tightening torque Bolt No. (9)

(5)

(7)

(16)

(5) — (15)

(17)

Tightening torque: N·m (kgf-m, ft-lb) 25 (2.5, 18.4)

10

40 (4.1, 29.5)

(11)

(13) (1)

(3)

(1) — (4) (16), (17)

(2)

(15)

(4) (14)

Bolt size mm 8

(10) (6)

(8) (12) MT-00003

6MT-4

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

2. DRIVE PINION ASSEMBLY (4) (5) (3) (2)

(15)

(1)

(16) (14) (13) (12)

(7) (11) (10)

T3

(29)

(9) (8) T1

(6)

(28) (27) (26) (25) T1 (24)

(23)

T2

(22) (35)

(21) (20) (19) (18) (30)

(17)

(33) (32) (30) (31)

(34)

MT-01870

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Drive pinion shaft Roller bearing Washer Thrust bearing Needle bearing Driven shaft Key Drive pinion collar Needle bearing 1st driven gear Inner baulk ring 1st synchro cone Outer baulk ring 1st-2nd synchronizer hub

(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)

1st-2nd shifting insert key 1st-2nd coupling sleeve Outer baulk ring 2nd synchro cone Inner baulk ring 2nd driven gear 2nd driven gear bushing 3rd-4th driven gear Driven pinion shim Double-row tapered roller bearing 5th driven gear Drive pinion spacer 6th driven gear Ball bearing

6MT-5

(29) (30) (31) (32) (33) (34) (35)

Lock nut Adjusting washer Thrust bearing Differential bevel gear sleeve Adjusting washer Lock washer Lock nut

Tightening torque:N·m (kgf-m, ft-lb) T1: 30 (3.1, 22.1) T2: 126 (12.8, 92.9) T3: 440 (44.9, 324.5)

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

3. MAIN SHAFT FOR SINGLE-RANGE

(3) (17) (2) (16) (15)

(1) (13) (11)

(14)

(12)

(10) (9)

(5)

(8) (7) (6)

(4)

T2 (32) (24) (31) (30) (29) (28) (27) (26) (25) (45)

(23)

(43)

(22) (21)

(42)

(37)

(41)

(20)

(51)

(19)

(50)

(18)

(49) (48)

(44)

(40) (39)

(33)

(38) (36) (35) (34)

(46) (47) T1 (52)

MT-02040

6MT-6

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL (1) (2)

Oil seal Needle bearing

(20) (21)

Main shaft rear plate 5th drive gear

(39) (40)

Baulk ring Reverse idler gear

(3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19)

Transmission main shaft Needle bearing 3rd drive gear Inner baulk ring 3rd synchro cone Outer baulk ring 3rd-4th coupling sleeve 3rd-4th synchronizer hub 3rd-4th shifting insert key 4th baulk ring 4th drive gear 4th needle bearing race Needle bearing 4th gear thrust washer Double-row tapered roller bearing 5th needle bearing race Needle bearing

(22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38)

5th baulk ring 5th-6th synchronizer hub 5th-6th shifting insert key 5th-6th coupling sleeve 6th baulk ring 6th drive gear 6th needle bearing race Needle bearing Ball bearing Lock washer Lock nut Reverse idler gear shaft Washer Needle bearing Reverse idler gear No. 2 Reverse shifting insert key Reverse coupling sleeve

(41) (42) (43) (44) (45) (46) (47) (48) (49) (50) (51) (52)

Reverse idler gear collar Needle bearing Washer Straight pin Oil case guide Reverse idler gear bushing Snap ring Reverse idler spring Reverse idler sub gear Friction plate Snap ring Gasket

6MT-7

Tightening torque:N·m (kgf-m, ft-lb) T1: 25 (2.5, 18.4) T2: 160 (16.3, 118.0)

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

4. SHIFTER FORK AND SHIFTER ROD (2)

(3)

(6) (15)

(5)

T

(3)

(1) (17) (16) (18) (14)

(4)

(13) (7) (3) (17) (16)

(8)

(15) (12)

(18) T

(13)

(9) (17) (16) (15)

(10)

(18)

(3) (12)

T (11)

(18) (17)

T

(16)

(3)

(15) MT-02128

(1) (2) (3) (4) (5) (6) (7)

Shifter arm Selector arm Spring pin Reverse shifter fork Reverse fork rod 5th-6th shifter fork 5th-6th fork rod

(8) (9) (10) (11) (12) (13) (14)

3rd-4th shifter fork 3rd-4th fork rod 1st-2nd shifter fork 1st-2nd fork rod Interlock plunger Interlock plunger Interlock plunger

6MT-8

(15) (16) (17) (18)

Checking ball plug Checking ball spring Check ball Gasket

Tightening torque:N·m (kgf-m, ft-lb) T: 20 (2.0, 14.8)

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

5. TRANSFER CASE AND EXTENSION T1

(24)

T1

T4 T1 (25)

(4)

(5) T5 T4

T2 (6) (26)

(8)

(27)

T7

(1) (30)

(2)

(22)

T3 (21)

T8 (3)

(9)

(7)

T7

(13)

(23)

(29) (12) (11)

T8 (10) (28)

(16) (19)

(15)

(20)

(18)

(14) (17)

T6

MT-02094

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Shifter arm Interlock plate Gasket Transfer case Transmission cover Gasket Gasket Neutral position switch Back-up light switch Roller bearing Transfer driven gear Roller bearing Adjusting washer Ball bearing

(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)

Center differential Adjusting washer Transfer drive gear Ball bearing Snap ring Extension case Bushing Oil seal Dust cover Transfer cover Dust cover Shift bracket Oil guide Outer race

6MT-9

(29) (30)

Outer race Gasket

Tightening torque:N·m (kgf-m, ft-lb) T1: 15 (1.5, 11.1) T2: 18 (1.8, 13.3) T3: 20 (2.0, 14.8) T4: 24.5 (2.5, 18.1) T5: 25 (2.5, 18.4) T6: 26 (2.7, 19.2) T7: 32.3 (3.3, 23.8) T8: 40 (4.1, 29.5)

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

6. SHIFT LINK ASSEMBLY (1)

T1 (5)

(12)

(15)

(5)

(6)

(20)

(25) (12)

(8)

(14)

(24) (24)

(10) (11) (10) (22)

(25)

(23)

(9)

T4

(13)

(7)

(15) T2 (19)

(3)

(4)

(17)

(21) (18)

(16)

T3

(2) (5) (20)

MT-02127

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Selector lever COMPL Selector arm No. 2 Shifter arm collar Neutral set spring Spring pin Selector arm Shifter arm Shift lever COMPL Shifter arm No. 2 Washer Thrust bearing

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Oil seal Straight pin Transfer case Gasket Checking ball spring Plunger Seal bolt Interlock plate Transmission cover Seal ring Washer

6MT-10

(23) (24) (25)

Neutral position switch Needle bearing Roller bearing

Tightening torque:N·m (kgf-m, ft-lb) T1: 6.4 (0.7, 4.7) T2: 20 (2.0, 14.8) T3: 25 (2.5, 18.4) T4: 32.3 (3.3, 23.8)

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

7. FRONT DIFFERENTIAL

(7) (5)

(6)

(1) (6) (5) (2)

(8)

(7) (3)

(4) T2

(8) (12)

(11 )

(10)

(10)

(12) (9)

(13)

(11 )

T1 T1

(13) MT-02095

(1) (2) (3) (4) (5) (6)

Drive pinion shaft Hypoid driven gear Pinion shaft STRAIGHT PIN Washer Differential bevel gear

(7) (8) (9) (10) (11) (12)

Differential bevel pinion Roller bearing Differential case Oil seal Differential side retainer O-ring

6MT-11

(13)

Retainer lock plate

Tightening torque:N·m (kgf-m, ft-lb) T1: 25 (2.5, 18.4) T2: 62 (6.3, 45.7)

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

8. TRANSMISSION MOUNTING (13)

(5)

(3) (4) (2)

(1) (9)

T4

T1 (7)

(8)

(2) (1) T2

(10)

(6) T1

T4

(14)

T3 T2

T3 (11) T5 T4 (12)

MT-02106

(1) (2) (3) (4)

Spacer Lower cushion rubber Front plate Transmission cushion rubber

(8) (9) (10) (11)

(5)

Rear crossmember (turbo model)

(12)

(6)

Upper cushion rubber

(13)

(7)

Center crossmember (turbo model)

(14)

Front crossmember Rear cushion rubber Rear plate Transmission main mounting bracket (RH) Transmission main mounting bracket (LH) Rear crossmember (non-turbo model) Center crossmember (non-turbo model)

6MT-12

Tightening torque:N·m (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 45 (4.6, 33.2) T3: 70 (7.1, 51.6) T4: 75 (7.6, 55.3) T5: 140 (14.3, 103.3)

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry apart with screwdrivers or other tools. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Use SUBARU genuine gear oil, grease or equivalent. Do not mix gear oil, grease, etc. of different grades or manufacturers. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Apply gear oil onto sliding or revolving surfaces before installation. • Replace deformed or damaged snap rings with new parts. • Before installing O-rings or oil seals, apply sufficient amount of gear oil to avoid damage and deformation. • Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts. • Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. • Avoid damaging the mating surface of the case. • Before applying liquid gasket, completely remove the old liquid gasket.

6MT-13

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 899524100

DESCRIPTION PULLER SET

REMARKS Used for removing the roller bearing (differential). (1) Puller (2) Cap

399780104

WEIGHT

Used for measuring preload on the roller bearing.

498077000

REMOVER

• Used for removing the roller bearing of the drive pinion shaft. • Used for removing the transfer driven gear taper roller bearing.

498077600

CENTER DIFFERENTIAL BEARING REMOVER

Used for removing the center differential cover ball bearing.

ST-899524100

ST-399780104

ST-498077000

ST-498077600

6MT-14

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION

TOOL NUMBER 498147001

DESCRIPTION DEPTH GAUGE

REMARKS Used for measuring the main shaft play.

498247001

MAGNET BASE

• Used for measuring backlash between the side gear and pinion, and the hypoid gear. • Used together with DIAL GAUGE (498247100).

498247100

Dial gauge

• Used for measuring backlash between the side gear and pinion, and the hypoid gear. • Used together with MAGNET BASE (498247001).

ST-498147001

ST-498247001

ST-498247100

18667AA020 HOLDER (Newly adopted tool)

Used for securing the drive pinion shaft assembly and the driven gear assembly when removing the drive pinion shaft assembly lock nut.

ST18667AA020

498937000

TRANSMISSION HOLDER

ST-498937000

6MT-15

Used for removing and installing the lock nut of the transmission main shaft.

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION

TOOL NUMBER 499277100

DESCRIPTION BUSHING 1-2 INSTALLER

REMARKS • Used for installing the 1st driven gear thrust plate and the 1st-2nd driven gear bushing. • Used for installing the roller bearing outer race to the differential case.

499277200

INSTALLER

Used for press-fitting the 2nd driven gear, roller bearings, 3rd-4th driven gear, 5th driven gear and the 6th driven gear onto the driven shaft.

499757002

INSTALLER

Used for installing the roller bearing of transfer driven gear (transfer case side).

ST-499277100

ST-499277200

ST-499757002

18658AA020 WRENCH COMPL (Newly adopted tool) RETAINER

• Used for removing and installing the differential side retainer. • Existing SST (18630AA010) with the handle bar removed. Use together with a commercially sold spinner handle. • WRENCH COMPL RETAINER (18630AA010) can also be used.

ST18658AA020

18722AA000

REMOVER

ST18722AA000

6MT-16

Used for removing the 5th drive gear and 6th drive gear.

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION

TOOL NUMBER 499877000

DESCRIPTION RACE 4-5 INSTALLER

REMARKS • Used for installing the 4th, 5th and 6th needle bearing races and ball bearings onto the transmission main shaft. • Used together with REMOVER (899714110).

499917500

DRIVE PINION GAUGE ASSY

Used for adjusting the drive pinion shim.

499927100

Handle

Used for backlash adjustment of the hypoid gear and preload measurement of the roller bearing.

499937100

TRANSMISSION STAND

Used for disassembling and assembling the transmission.

499987003

SOCKET WRENCH (35)

Used for removing and installing the main shaft lock nut.

ST-499877000

ST-499917500

ST-499927100

ST-499937100

ST-499987003

6MT-17

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION

TOOL NUMBER 499987300

DESCRIPTION SOCKET WRENCH (50)

REMARKS Used for removing and installing the driven gear assembly lock nut.

899714110

REMOVER

Used for removing and installing the parts of transmission main shaft, drive pinion and rear drive shaft.

899864100

REMOVER

Used for removing and installing the parts of transmission main shaft, and the transfer driven gear roller bearing.

ST-499987300

ST-899714110

ST-899864100

18680AA020 HOLDER (Newly adopted tool)

Used for removing and installing the drive pinion lock nut.

ST18680AA020

899904100

REMOVER

ST-899904100

6MT-18

Used for removing and installing the straight pin.

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION

TOOL NUMBER 398497701

DESCRIPTION Adapter

REMARKS • Used for installing roller bearing onto the differential case. • Used together with BUSHING 1-2 INSTALLER (499277100).

498057300

INSTALLER

Used for installing the extension oil seal.

498255400

PLATE

Used for measuring backlash.

398527700

PULLER ASSY

• Used for removing the extension case roller bearing. • Used for removing the extension oil seal. • Used for removing the front differential side retainer bearing outer race. • Used for removing the front differential side retainer oil seal.

398643600

GAUGE

Used for measuring total end play, extension end play and drive pinion height.

ST-398497701

ST-498057300

ST-498255400

ST-398527700

ST-398643600

6MT-19

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION

TOOL NUMBER 398177700

DESCRIPTION INSTALLER

REMARKS • Used for fitting the transfer drive shaft. • Used for installing the roller bearing of the transfer driven gear. • Used for installing the 4th needle bearing race of transmission main shaft.

ST-398177700

28399SA010

OIL SEAL PROTEC- Used for protecting the oil seal from damage when inserting the front drive shaft. TOR

18675AA000

DIFFERENTIAL SIDE OIL SEAL INSTALLER

Used for installing the differential side retainer oil seal.

SPRING PIN REMOVER 2

Used for installing and removing the spring pin.

ST28399SA010

ST18675AA000

398791700

ST-398791700

18662AA010 SOCKET (27) (Newly adopted tool)

ST18662AA010

6MT-20

Used for removing and installing the drive pinion lock nut.

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION

TOOL NUMBER 899754112

DESCRIPTION PRESS

REMARKS • Used for removing the driven gear and roller bearing of the driven shaft. • Used to install the main shaft ball bearing.

18631AA000

Handle

Used for installing transfer case assembly and extension case assembly.

18762AA000

COMPRESSOR SPECIAL TOOL

Used for removing the 1st driven gear of drive pinion.

18654AA000

INSTALLER

Used for installing the 2nd driven gear bushing of driven shaft.

18657AA000

INSTALLER

Used for installing the transfer case oil seal.

ST-899754112

ST18631AA000

ST18762AA000

ST18654AA000

ST18657AA000

6MT-21

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General Description MANUAL TRANSMISSION AND DIFFERENTIAL ILLUSTRATION

TOOL NUMBER DESCRIPTION 41099AJ000 SPECIAL (Newly adopted tool) TOOL H4

REMARKS Used for removing and installing transmission.

99099AJ000 SPECIAL (Newly adopted tool) TOOL ENGINE HANGER

• Used for removing and installing transmission. (Weight of 350 kg (772 lb) is supported) • Used together with SPECIAL TOOL CHAIN BALANCER (99099AJ010) and sling chain (general tool).

99099AJ010 SPECIAL (Newly adopted tool) TOOL CHAIN BALANCER

• Used for removing and installing transmission. (Weight of 350 kg (772 lb) is supported) • Used together with SPECIAL TOOL ENGINE HANGER (99099AJ000) and sling chain (general tool). • Used to hang the engine while balancing it with the sling chain inserted in this tool.

ST41099AJ000

ST99099AJ000

ST99099AJ010

2. GENERAL TOOL TOOL NAME Circuit tester TORX® bit T70 Spring pin remover Socket driver (TORX®45 size, tamper resistant type) Sling chain

Screw shackle

REMARKS Used for measuring resistance. Used for installing and removing the differential gear oil drain plug. Used for removing and installing the spring pin. (3 — 3.3 mm) Used for removing and installing interlock plate. Used for removing and installing transmission. • Length: 0.8 — 1 m (2.6 — 3.3 ft) • Load capacity: 1.2 t (2646 lb) or more • Diameter: 6 mm (0.24 in) or 6.3 mm (0.25 in) • Chain external width: 23.5 mm (0.93 in) or less • Chain internal width: 8.5 mm (0.33 in) or more Used for removing and installing transmission. • Load capacity: 250 kg (551 lb) or more • Use two pieces.

6MT-22

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Transmission Gear Oil MANUAL TRANSMISSION AND DIFFERENTIAL

2. Transmission Gear Oil A: INSPECTION 1) Park the vehicle on a level surface. 2) Turn the ignition switch to OFF, and wait until the engine cools. 3) Remove the collector cover. 4) Remove the oil level gauge and wipe it clean. 5) Reinsert the oil level gauge all the way. Be sure that the oil level gauge is correctly inserted in the proper direction. 6) Pull out the oil level gauge again, and check the oil level. If it is below the lower level, add oil through the oil level gauge hole to bring the level up to the upper level.

Tightening torque: 44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket silver) 70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket brown) 70 N·m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket black)

MT-01548

(A)

5) Lower the vehicle. 6) Pour gear oil through the oil level gauge hole. (B)

Recommended gear oil: GL-5 (75W-90) or equivalent

(C)

Gear oil capacity: 3.7 2 (3.9 US qt, 3.3 Imp qt) 7) Measure the transmission gear oil amount, and check that it is within the specification.

MT-02052

(A) Oil level gauge (B) Upper level (C) Lower level

B: REPLACEMENT 1) Pull out the oil level gauge. 2) Lift up the vehicle. 3) Using the TORX® bit T70, remove the drain plug, and drain the transmission gear oil completely.

CAUTION: When inserting the oil level gauge into the transmission, align the protrusion on top of the oil level gauge with the notch in the oil level gauge hole. 8) Install the collector cover.

CAUTION: • Immediately after the engine has been running, the transmission gear oil will be hot. Be careful not to burn yourself. • Be careful not to spill the transmission gear oil on exhaust pipe to prevent it from emitting smoke or causing fires. If gear oil is spilt wipe it off completely. 4) Using the TORX® bit T70, tighten the transmission gear oil drain plug. NOTE: • Tighten the drain plug of the transmission gear oil after draining the transmission gear oil. • Use a new gasket.

6MT-23

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Manual Transmission Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

3. Manual Transmission Assembly

11) Disconnect the connector of back-up light switch and neutral position switch. • Non-turbo model

A: REMOVAL 1) Set the vehicle on a lift. 2) Remove the front wheels. 3) Open the front hood completely. 4) Remove the collector cover. 5) Remove the air intake duct. 6) Remove the 10 clips and detach the grille bracket.

(A)

(B) MT-02082

(A) Neutral position switch connector (Brown) (B) Back-up light switch connector (gray)

• Turbo model

(A)

(B)

CO-02594

7) Disconnect the ground cable from battery. 8) Remove the air intake boot assembly. (non-turbo model) 9) Remove the intercooler and the intercooler stay. (turbo model) 10) Disconnect the engine harness connector. • Non-turbo model

MT-02083

(A) Neutral position switch connector (Brown) (B) Back-up light switch connector (gray)

12) Disconnect the ground cable. • Non-turbo model

MT-02080 MT-02084

• Turbo model

MT-02081

6MT-24

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Manual Transmission Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

• Turbo model

21) Remove the heat shield cover.

MT-02085

MT-01660

13) Remove the throttle body. (non-turbo model)

14) Remove the starter. 15) Remove the operating cylinder from the transmission, and hang it with a wire or the like.

MT-02044

16) Lift up the vehicle. 17) Remove the front under cover. 18) Drain transmission gear oil completely. 19) Remove the front, center and rear exhaust pipes. (non-turbo model)

20) Remove the center and rear exhaust pipes. (turbo model)

22) Remove the steering shaft universal joint.

23) Remove the propeller shaft. 24) Remove the MT gear shift cable and MT gear select cable from MT gear shift lever. CAUTION: • Do not bend MT gear shift cable and MT gear select cable at a sharp angle. • Disconnect the MT gear shift cable and MT gear select cable at the MT gear shift lever side. • Always use new MT gear select cable if the cable is removed from selector lever COMPL of transmission side. 25) Remove the stabilizer link from the front arm.

26) Remove the bolts which secure front arm ball joint to the housing, and separate the front arm and housing. 27) Separate the front drive shafts on both sides from the transmission. 28) Lower the vehicle. 29) Remove the engine hanger rear, and install the engine hanger rear for turbo model. (non-turbo model)

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb) Part No. 10004AA180 Engine hanger rear

CAUTION: When removing the exhaust pipes, make sure that each exhaust pipe does not drop off.

MT-02086

6MT-25

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Manual Transmission Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

30) Remove the nuts connecting the engine mounting and the transmission main mounting bracket.

RH

• Set the arms of ST (ENGINE HANGER) at the locations shown in the figure. ST1 99099AJ000 SPECIAL TOOL ENGINE HANGER ST2 99099AJ010 SPECIAL TOOL CHAIN BALANCER GENERAL TOOL Sling chain GENERAL TOOL Screw shackle ST2

ST1

LH

AT-05582

ST2

ST1

MT-02057

31) Set the ST on the vehicle and hang the engine. CAUTION: • Set the ST so that the chain does not contact the sensor and other parts while hanging the engine.

AT-05583

32) Remove the stopper rod.

MT-02058

33) Remove the front cushion rubbers.

MT-02059

34) Attach the ST with the front cushion rubber mounting bolts and nuts.

6MT-26

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Manual Transmission Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

CAUTION: Do not tighten the nuts on the engine mount excessively, or the engine mounting bracket may be deformed.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) ST 41099AJ000 SPECIAL TOOL

37) Remove the bolts which hold upper side of transmission to engine.

H4

MT-01524

ST

38) Attach the ST (ENGINE HANGER) again. 39) Lift up the vehicle. 40) Remove the bolts and nuts which hold lower side of transmission to engine. MT-02060

35) Remove the ST (ENGINE HANGER). NOTE: Operation is less efficient with the ST (ENGINE HANGER) attached. Remove it temporarily. 36) Remove the transmission main mounting bracket.

RH

MT-00077

41) Place the transmission jack under the transmission. CAUTION: Always support the transmission case with a transmission jack.

LH

MT-00078

42) Remove the front crossmember and rear crossmember from the vehicle. MT-02061

MT-02074

6MT-27

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Manual Transmission Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

43) Remove the transmission while lowering the transmission jack. NOTE: Move the transmission jack towards the rear until the main shaft is withdrawn from the clutch disc. 44) Separate the transmission assembly from the transmission cushion rubber.

CAUTION: Do not apply excessive load or impact to the transmission case.

B: INSTALLATION 1) Replace the differential side retainer oil seal.

NOTE: Be sure to replace the differential side retainer oil seal after removing the front drive shaft. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER

MT-02101

5) Install the transmission onto the engine. (1) Lift up the transmission gradually using a transmission jack. (2) Engage at the spline section. NOTE: Be careful not to hit the main shaft against the clutch housing cover. 6) Temporarily tighten the bolts and nuts which hold lower side of transmission to engine. 7) Install the front crossmember and rear crossmember.

ST

MT-00103

2) Install the transmission cushion rubber to the transmission assembly, and tighten bolt (A). 3) Install the transmission cushion rubber to the center crossmember, and tighten nut (B).

Tightening torque: T1: 75 N·m (7.6 kgf-m, 55.3 ft-lb) T2: 140 N·m (14.3 kgf-m, 103.3 ft-lb) T1

Tightening torque: Bolt (A) 35 N·m (3.6 kgf-m, 25.8 ft-lb) Nut (B) 35 N·m (3.6 kgf-m, 25.8 ft-lb)

T2

T1

T2

MT-02076

8) Take out the transmission jack. 9) Tighten the bolts and nuts which hold the lower side of transmission to the engine. (A)

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

(A)

(B)

MT-02075

4) Tap the transmission hanger in the rear side of transmission with a rubber hammer to bend it until it is in close contact with the transmission case.

MT-00077

6MT-28

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Manual Transmission Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

10) Lower the vehicle. 11) Tighten the bolts which hold the upper side of the transmission to the engine.

Tightening torque: T1: 25 N·m (2.5 kgf-m, 18.4 ft-lb) T2: 45 N·m (4.6 kgf-m, 33.2 ft-lb)

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb) T1

T1

T2

MT-02105

16) Install the stopper rod. MT-01524

12) Remove the ST (ENGINE HANGER). 13) Install the transmission main mounting bracket.

Tightening torque: 36 N·m (3.7 kgf-m, 26.6 ft-lb)

Tightening torque: 75 N·m (7.6 kgf-m, 55.3 ft-lb)

RH

MT-02058

17) Remove the ST from the vehicle. 18) Tighten the nuts connecting the engine mount and the transmission main mounting bracket.

Tightening torque: 45 N·m (4.6 kgf-m, 33.2 ft-lb)

LH

RH

MT-02061

14) Attach the ST (ENGINE HANGER) again. 15) Remove the ST and install the front cushion rubber.

LH

MT-02057

6MT-29

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Manual Transmission Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

19) Remove the engine hanger rear for turbo model and install the engine hanger rear for non-turbo model. (non-turbo model)

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb) 20) Install the starter. 21) Install the operating cylinder. Tightening torque: 37 N·m (3.8 kgf-m, 27.3 ft-lb)

MT-02044

22) Lift up the vehicle. 23) Install the front drive shaft into the transmission. ST 28399SA010 OIL SEAL PROTECTOR 24) Insert the front arm ball joint into the housing lower part. 25) Attach the stabilizer link to the front arm. 26) Install the MT gear shift cable and MT gear select cable to MT gear shift lever. CAUTION: • Do not bend MT gear shift cable and MT gear select cable at a sharp angle. • Always use new MT gear select cable if the cable is removed from selector lever COMPL of transmission side. 27) Install the propeller shaft. 28) Install the steering shaft universal joint. 29) Install the heat shield cover. 30) Install the front, center and rear exhaust pipe. (non-turbo model)

31) Install the center and rear exhaust pipe. (turbo model) 32) Install the front under cover. 33) Lower the vehicle. 34) Install the throttle body. (non-turbo model)

35) Connect the following connectors. (1) Transmission ground cable

Tightening torque: 13 N·m (1.3 kgf-m, 9.6 ft-lb) (2) Neutral position switch connector (Brown) (3) Back-up light switch connector (gray) (4) Engine harness connectors 36) Fill transmission gear oil through the transmission oil level gauge hole. 37) Install the air intake boot assembly. (non-turbo model) 38) Install the intercooler and the intercooler stay. (turbo model) 39) Attach the grille bracket.

CO-02594

40) Install the air intake duct. 41) Install the collector cover. 42) Install the front wheels. 43) Connect the ground cable to battery.

6MT-30

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Transmission Mounting System MANUAL TRANSMISSION AND DIFFERENTIAL

4. Transmission Mounting System A: REMOVAL 1. CROSSMEMBER AND CUSHION RUBBER 1) Disconnect the ground cable from battery. 2) Lift up the vehicle. 3) Remove the front under cover. 4) Remove the front and center exhaust pipes. (non-turbo model) 5) Remove the center exhaust pipe. (turbo model)

6) Remove the heat shield cover.

B: INSTALLATION 1. CROSSMEMBER AND CUSHION RUBBER 1) Install the transmission cushion rubber to the transmission, and tighten the bolt (A). 2) Attach the transmission cushion rubber to the center crossmember, and tighten nut (B).

Tightening torque: Bolt (A) 35 N·m (3.6 kgf-m, 25.8 ft-lb) Nut (B) 35 N·m (3.6 kgf-m, 25.8 ft-lb)

(A) (A)

(B)

MT-02075

3) Install the front crossmember and rear crossmember.

Tightening torque: T1: 75 N·m (7.6 kgf-m, 55.3 ft-lb) T2: 140 N·m (14.3 kgf-m, 103.3 ft-lb)

MT-01660

7) Set the transmission jack under transmission. CAUTION: Always support the transmission case with a transmission jack. 8) Remove the front crossmember and rear crossmember.

T1

T2

T1

T2

MT-02076

MT-02074

9) Remove the transmission cushion rubber.

4) Remove the transmission jack. 5) Install the heat shield cover. 6) Install the front and center exhaust pipe. (nonturbo model) 7) Install the center exhaust pipe. (turbo model)

8) Install the front under cover. 9) Lower the vehicle. 10) Connect the ground cable to battery.

6MT-31

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Transmission Mounting System MANUAL TRANSMISSION AND DIFFERENTIAL

C: INSPECTION Perform the following inspection procedures and repair or replace faulty parts.

1. CROSSMEMBER AND CUSHION RUBBER Check crossmember for bends or damage. Check that the cushion rubber is not stiff, cracked, or otherwise damaged.

6MT-32

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Oil Seal MANUAL TRANSMISSION AND DIFFERENTIAL

5. Oil Seal

9) Remove the heat shield cover.

A: INSPECTION Check for transmission gear oil leaks at oil seal area. If there is an oil leak, replace the oil seal with new one and check the propeller shaft.

B: REPLACEMENT 1) Remove the collector cover. 2) Lift up the vehicle. 3) Remove the front under cover. 4) Clean the transmission exterior. 5) Using the TORX® bit T70, remove the drain plug, and drain the transmission gear oil completely. 6) Using the TORX® bit T70, tighten the transmission gear oil drain plug.

MT-01660

10) Remove the propeller shaft. 11) Using the ST, remove the oil seal. ST 398527700 PULLER ASSY ST

(A)

NOTE: Use a new gasket.

Tightening torque: 44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket silver) 70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket brown) 70 N·m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket black)

MT-01849

(A) Oil seal

12) Using the ST, install the oil seal. ST 498057300 INSTALLER ST

MT-01548

7) Remove the center and rear exhaust pipes. (non-turbo model) 8) Remove the center and rear exhaust pipes. (turbo model)

MT-01850

13) Apply transmission gear oil to the oil seal lips. 14) Install the propeller shaft. 15) Install the heat shield cover. 16) Install the center and rear exhaust pipe. (nonturbo model)

6MT-33

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Oil Seal MANUAL TRANSMISSION AND DIFFERENTIAL

17) Install the center and rear exhaust pipe. (turbo model) 18) Install the front under cover. 19) Lower the vehicle. 20) Pour in transmission gear oil and check the oil level. 21) Install the collector cover.

6MT-34

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Differential Side Retainer Oil Seal MANUAL TRANSMISSION AND DIFFERENTIAL

6. Differential Side Retainer Oil Seal A: INSPECTION Check for leakage of transmission gear oil from the differential side retainer oil seal. If there is oil leakage, replace the oil seal with the new part and check the drive shaft.

B: REPLACEMENT 1) Remove the collector cover. 2) Lift up the vehicle. 3) Remove the front under cover. 4) Using the TORX® bit T70, remove the oil drain plug, and drain the transmission gear oil completely.

8) Separate the front drive shaft from the transmission. 9) Remove the differential side retainer oil seal. NOTE: • Be sure to replace the differential side retainer oil seal whenever the front drive shaft is removed from the transmission. • Use the ST 398527700 PULLER ASSY to remove the oil seal. If removing the oil seal with a flat tip screwdriver, be careful not to scratch the differential side retainer. 10) Using the ST, install the differential side retainer oil seal by lightly tapping with a plastic hammer. NOTE: • Apply transmission gear oil to the oil seal lips, and install the oil seal while being careful not to deform the lip. • Check the identification marks (L, R) during installation not to mix up the oil seal RH and LH. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER ST

MT-01548

5) Tighten the oil drain plug using TORX® bit T70. NOTE: Use a new gasket.

Tightening torque: 44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket silver) 70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket brown) 70 N·m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket black)

MT-00103

11) Install the front drive shaft. 12) Install the center exhaust pipe. (non-turbo model) 13) Install the center exhaust pipe. (turbo model)

14) Install the front under cover. 15) Lower the vehicle. 16) Add the transmission gear oil through the oil level gauge hole. 17) Install the collector cover.

MT-01548

6) Remove the center exhaust pipe. (non-turbo model) 7) Remove the center exhaust pipe. (turbo model)

6MT-35

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Switches and Harness MANUAL TRANSMISSION AND DIFFERENTIAL

7. Switches and Harness

7) Remove the back-up light switch and neutral position switch together with harness.

A: REMOVAL 1. BACK-UP LIGHT SWITCH & NEUTRAL POSITION SWITCH

(A)

1) Disconnect the ground cable from battery. 2) Remove the collector cover. 3) Remove the air intake boot assembly. (non-turbo model) 4) Remove the intercooler. (turbo model) 5) Disconnect the connector of back-up light switch and neutral position switch. • Non-turbo model

(B) MT-01843

(A) Neutral position switch (B) Back-up light switch

B: INSTALLATION 1. BACK-UP LIGHT SWITCH & NEUTRAL POSITION SWITCH

(A)

1) Install the back-up light switch and neutral position switch together with harness.

Tightening torque: 32.3 N·m (3.3 kgf-m, 23.8 ft-lb)

(B) MT-02082

(A)

(A) Neutral position switch connector (Brown) (B) Back-up light switch connector (gray)

• Turbo model

(A)

(B) MT-01843

(A) Neutral position switch (B) Back-up light switch

(B)

MT-02083

(A) Neutral position switch connector (Brown) (B) Back-up light switch connector (gray)

6) Lift up the vehicle.

2) Lower the vehicle. 3) Connect the connector of back-up light switch and neutral position switch. 4) Install the air intake boot assembly. (non-turbo model) 5) Install the intercooler. (turbo model) 6) Install the collector cover. 7) Connect the ground cable to battery.

6MT-36

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Switches and Harness MANUAL TRANSMISSION AND DIFFERENTIAL

C: INSPECTION 1. BACK-UP LIGHT SWITCH Check the back-up light switch.

2. NEUTRAL POSITION SWITCH 1) Turn the ignition switch to OFF. 2) Disconnect the connector of neutral position switch. 3) Measure the resistance between neutral position switch terminals.

2 1

MT-00110

Gear shift position Neutral position Other positions

Terminal No. 1 and 2

Specified resistance Less than 1 Ω 1 MΩ or more

4) Replace faulty parts.

6MT-37

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Preparation for Overhaul MANUAL TRANSMISSION AND DIFFERENTIAL

8. Preparation for Overhaul A: PROCEDURE 1) Clean oil, grease, dirt and dust from the transmission. 2) Using the TORX® bit T70, remove the transmission gear oil drain plug, and drain the transmission gear oil completely. 3) Using the TORX® bit T70, tighten the transmission gear oil drain plug. NOTE: Use a new gasket.

Tightening torque: 44 N·m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket silver) 70 N·m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket brown) 70 N·m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket black)

MT-01548

4) Attach the transmission to the ST. ST 499937100 TRANSMISSION STAND

ST

MT-00115

5) Apply oil to rotating parts before assembly. 6) All disassembled parts, if to be reused, should be reinstalled in the original positions and directions. 7) Gaskets, lock washers and lock nuts must be replaced with new ones. 8) Apply liquid gasket to the specified areas to prevent leakage.

6MT-38

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Transfer Case and Extension Case Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

9. Transfer Case and Extension Case Assembly

5) Use the ST to push out the spring pin and remove the shift lever COMPL from shifter arm No. 2. ST 398791700 SPRING PIN REMOVER 2

A: REMOVAL

(B)

1) Remove the manual transmission assembly from the vehicle. 2) Remove the back-up light switch neutral position switch. 3) Remove the transfer case together with the extension case assembly. (1) Remove the transmission cover.

(A)

(A)

MT-01875

(A) Shift lever COMPL (B) Spring pin

6) Remove the extension case assembly.

MT-01963

(A) Transmission cover

(2) Set and hold the selector lever COMPL to the 1st-2nd side, and remove the transfer case and extension case assembly as a unit.

MT-01930

B: INSTALLATION 1) Install the center differential and transfer driven gear into the transfer case.

MT-01929

4) Remove the transfer cover. MT-01893

MT-01874

6MT-39

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Transfer Case and Extension Case Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

2) Remove the bearing outer race from the extension case.

7) Select the washer with the nearest value in the following table.

Preload of the taper roller bearing (amount of standard protrusion): 0.15 — 0.20 mm (0.006 — 0.008 in)

(B) (A)

NOTE: Be sure that it is always within the preload. Thrust washer (50 × 61 × t) Part number Thickness mm (in) 803050060 0.50 (0.0197) 803050061 0.55 (0.0217) 803050062 0.60 (0.0236) 803050063 0.65 (0.0256) 803050064 0.70 (0.0276) 803050065 0.75 (0.0295) 803050066 0.80 (0.0315) 803050067 0.85 (0.0335) 803050068 0.90 (0.0354) 803050069 0.95 (0.0374) 803050070 1.00 (0.0394) 803050071 1.05 (0.0413) 803050072 1.10 (0.0433) 803050073 1.15 (0.0453) 803050074 1.20 (0.0472) 803050075 1.25 (0.0492) 803050076 1.30 (0.0512) 803050077 1.35 (0.0531) 803050078 1.40 (0.0551) 803050079 1.45 (0.0571)

MT-01894

(A) Bearing outer race (B) Extension case

3) While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns. 4) Measure the height “W” between transfer case and taper roller bearing on the transfer driven gear.

W

MT-00120

W Measured value

5) Measure depth “X” on bearing insertion part of the extension case. NOTE: Measure with bearing outer race and thrust washer removed.

8) Fit the thrust washers on the transfer drive shaft. 9) Install the bearing outer race into the extension case. 10) Measure the depth “S” between transfer case and center differential. ST 398643600 GAUGE ST

S X

MT-00121 MT-00122

X Measured value

S Measured value

6) Calculate the thrust washer thickness “t” using the following calculation. t = X – W + (0.15 — 0.20 mm (0.006 — 0.008 in))

6MT-40

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Transfer Case and Extension Case Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

11) Measure the height “T” between the extension case and transfer drive gear. ST 398643600 GAUGE

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

ST

T

MT-00123

MT-01993

16) Install the extension case assembly to the transfer case.

T Measured value

12) Calculate the thrust washer thickness “U” using the following calculation. U = S + T – 30 mm (1.18 in) [Thickness of ST]

Tightening torque: 40 N·m (4.1 kgf-m, 29.5 ft-lb)

NOTE: Thickness of ST: 15 mm (0.59 in) 13) Select a suitable washer in the following table.

Standard clearance: 0.15 — 0.35 mm (0.0059 — 0.0138 in) Part number 803036050 803036054 803036051 803036055 803036052 803036056 803036053 803036057 803036058 803036080 803036081

Thrust washer Thickness mm (in) 0.9 (0.035) 1.0 (0.039) 1.1 (0.043) 1.2 (0.047) 1.3 (0.051) 1.4 (0.055) 1.5 (0.059) 1.6 (0.063) 1.7 (0.067) 1.8 (0.071) 1.9 (0.075)

MT-01930

17) Install the extension case assembly along with the transfer case to the transmission case.

14) Fit the thrust washer onto the center differential. 15) Apply a proper amount of liquid gasket to the transfer case mating surface.

6MT-41

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Transfer Case and Extension Case Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

(1) Insert the axle shaft and hold, then move the HANDLE to align the spline position to install. ST 18631AA000 HANDLE Part No. 38415AA100 Axle shaft

(2) Set and hold the selector lever to the 1st2nd side, and install the transfer case assembly so that the shifter arm edge and fork rod does not contact.

MT-01966

18) Temporarily tighten the transfer case assembly. 19) Install the shift lever COMPL to the shifter arm No. 2, then insert the remover or similar tool instead of spring pin. (B)

ST

MT-02043

NOTE: Push the transfer case assembly until the knock pin protrudes slightly from the transfer case. (A) (A)

(B)

MT-02006

(A) Shift lever COMPL (B) REMOVER

20) Operate the selector arm and remover to confirm the correct shifting into each gear is possible. 21) Tighten the transfer case assembly to the specified torque. (C) MT-02004

Tightening torque: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)

(A) Transmission case (B) Transfer case (C) Knock pin

MT-02005

22) Install the shift lever COMPL to the shifter arm No. 2, then fix it using a spring pin.

6MT-42

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Transfer Case and Extension Case Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY

NOTE: Use new spring pin.

1. TRANSFER CASE (B)

1) Remove the interlock plate. NOTE: Do not attempt to replace the interlock plate unless necessary. Do not reuse the bolts and gaskets once they are removed.

(A)

MT-01875

(A) Shift lever COMPL (B) Spring pin (A)

23) Install the transfer cover. (1) Temporarily tighten the transfer cover mounting bolts. (2) Tighten bolts in order of (B), (A), (C), (D) to the specified torque.

MT-01899

(A) Interlock plate

2) Remove the shift link assembly.

Tightening torque: 15 N·m (1.5 kgf-m, 11.1 ft-lb)

2. EXTENSION CASE

(D)

1) Remove the transfer drive gear assembly. 2) Remove the oil seal from the extension case.

(A)

D: ASSEMBLY 1. TRANSFER CASE (B)

(C)

MT-01887

24) Install the transmission cover.

1) Install the shift link assembly to the transfer case. 2) Install the interlock plate to the transfer case. NOTE: • Use a new bolt and gasket. • Before installing the interlock plate, clean the screw threads.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb)

(A)

MT-01899

(A) Interlock plate

6MT-43

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Transfer Case and Extension Case Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

2. EXTENSION CASE 1) Using the ST, install the oil seal to the extension case. NOTE: Use a new oil seal. 2) Install the transfer drive gear to the extension case.

6MT-44

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Transfer Drive Gear MANUAL TRANSMISSION AND DIFFERENTIAL

10.Transfer Drive Gear

C: DISASSEMBLY

A: REMOVAL

1) Remove the snap ring.

1) Remove the manual transmission assembly from the vehicle. 2) Remove the back-up light switch neutral position switch. 3) Remove the transfer case together with the extension case assembly. 4) Remove the extension case assembly. 5) Remove the transfer driven gear. 6) Remove the transfer drive gear.

MT-01967

2) Remove the ball bearing. ST 899864110 REMOVER ST

MT-01969

D: ASSEMBLY

MT-01876

1) Set the ST to the bearing inner race, then install the transfer drive shaft.

B: INSTALLATION 1) Install the transfer drive gear.

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST 398177700 INSTALLER

Tightening torque: 26 N·m (2.7 kgf-m, 19.2 ft-lb)

ST

MT-01876

2) Install the transfer driven gear. 3) Install the extension case assembly. 4) Install the transfer case and the extension case assembly. 5) Install the back-up light switch neutral position switch. 6) Install the manual transmission assembly to the vehicle.

MT-01970

2) Install the snap ring on the transfer drive shaft.

6MT-45

MT-01967

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Transfer Drive Gear MANUAL TRANSMISSION AND DIFFERENTIAL

3) Inspect the clearance between the snap ring and the ball bearing.

E: INSPECTION 1) Bearing Replace the bearings in the following cases. • In case of broken or rusty bearings • In case of wear or damage • When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication. 2) Drive gear If the drive gear tooth surface and shaft are excessively broken or damaged, replace the drive gear. 3) Measure the clearance between snap ring and inner race of ball bearing with a thickness gauge.

Clearance: 0.01 — 0.15 mm (0.0004 — 0.0059 in)

MT-01968

If the measurement is not within specification, select a suitable snap ring and replace it. Snap ring (Outer-30) Part number Thickness mm (in) 805030041 1.53 (0.0602) 805030042 1.65 (0.0650) 805030043 1.77 (0.0697)

6MT-46

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Transfer Driven Gear MANUAL TRANSMISSION AND DIFFERENTIAL

11.Transfer Driven Gear

B: INSTALLATION

A: REMOVAL

1) Install the bearing outer races to extension case and transfer case.

1) Remove the manual transmission assembly from the vehicle. 2) Remove the back-up light switch neutral position switch. 3) Remove the transfer case together with the extension case assembly. 4) Remove the extension case assembly. 5) Remove the transfer driven gear.

(C) (A)

(B)

MT-01896

MT-01893

6) Remove bearing outer races from the extension case and transfer case.

(A)

(D)

(A) (B) (C) (D)

Bearing outer race Bearing outer race Transfer case Extension case

2) Install the transfer driven gear.

(B) MT-01893

MT-01895

(A) Bearing outer race (Transfer case side) (B) Bearing outer race (Extension case side)

3) Install the transfer case and the extension case assembly. 4) Install the back-up light switch neutral position switch. 5) Install the manual transmission assembly to the vehicle.

6MT-47

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Transfer Driven Gear MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY 1) Using the ST, remove the roller bearing (extension case side). ST 498077000 REMOVER

2) Using ST, install the roller bearing (transfer case side). CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST 499757002 INSTALLER ST

ST

(A)

(A)

MT-00143

(A) Roller bearing

MT-00146

2) Using ST1 and ST2, remove the roller bearing (transfer case side). ST1 498077000 REMOVER ST2 899864100 REMOVER

ST2

(A) ST1

(A) Roller bearing

E: INSPECTION 1) Bearing Replace the bearings in the following cases. • In case of broken or rusty bearings • In case of wear or damage • When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication. 2) Driven gear If the tooth face of driven gear and the shaft are excessively broken or damaged, replace the driven gear.

MT-00144

(A) Roller bearing

D: ASSEMBLY 1) Using the ST, install the roller bearing (extension case side). CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 398177700 INSTALLER ST2 899864100 REMOVER ST2

(A)

ST1

MT-00145

(A) Roller bearing

6MT-48

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Center Differential MANUAL TRANSMISSION AND DIFFERENTIAL

12.Center Differential

C: DISASSEMBLY

A: REMOVAL

NOTE: • Center differential is a non-disassembled part which should not be disassembled. • Remove the ball bearing using ST. • Do not reuse the ball bearing. ST 498077600 CENTER DIFFERENTIAL BEARING REMOVER

1) Remove the manual transmission assembly from the vehicle. 2) Remove the back-up light switch neutral position switch. 3) Remove the transfer case together with the extension case assembly. 4) Remove the extension case assembly. 5) Remove the transfer driven gear. 6) Remove the center differential.

ST

MT-01897

B: INSTALLATION

D: ASSEMBLY

1) Install the center differential into transfer case. 2) Install the transfer driven gear. 3) Install the extension case assembly. 4) Install the transfer case together with the extension case assembly. 5) Install the back-up light switch neutral position switch. 6) Install the manual transmission assembly to the vehicle.

Install the ball bearing to the center differential assembly. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Use a new ball bearing.

(A) MT-01898

(A) Ball bearing

E: INSPECTION 1) Bearing Replace the bearings in the following cases. • In case of broken or rusty bearings • In case of wear or damage • When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication. • When bearing has other defects. 2) Center differential If there is wear or damage, replace the center differential case assembly.

6MT-49

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Shift Link Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

13.Shift Link Assembly

6) Drive out the spring pin by tapping with the ST, and remove the select lever COMPL. ST 398791700 SPRING PIN REMOVER 2

A: REMOVAL 1) Remove the manual transmission assembly from the vehicle. 2) Remove the back-up light switch neutral position switch. 3) Remove the transfer case together with the extension case assembly. 4) Remove the extension case assembly. 5) Pull out the straight pin. (B)

ST

(A) (C)

(B)

(A) (B)

(A)

MT-01902 MT-01901

(A) Selector lever COMPL (A) Selector lever COMPL (B) Straight pin

(B) Selector arm No. 2 (C) Spring pin

7) Pull out the selector arm No. 2 from neutral set spring.

(A)

(B) MT-01903

(A) Selector arm No. 2 (B) Neutral set spring

6MT-50

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Shift Link Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

8) Remove the shifter arm collar and neutral set spring from transfer case.

10) Drive out the spring pin by tapping with the ST, and remove the shifter arm and selector arm. ST 398791700 SPRING PIN REMOVER 2

(B)

ST (C) (A) MT-01906

(A) Shifter arm (B) Selector arm (C) Spring pin

(A)

11) Remove the oil seal from transfer case using a screwdriver.

(B)

NOTE: The illustration shows the oil seal of select lever COMPL. Perform the same procedures for removing the shifter arm No. 2.

MT-01904

(A) Shifter arm collar (B) Neutral set spring (A)

9) Remove the shifter arm No. 2, washers and thrust bearing from transfer case. (B) (C) (B)

MT-02007

(A)

(A) Oil seal

MT-01905

(A) Shifter arm No. 2 (B) Washer (C) Thrust bearing

12) Remove the needle bearing from the transfer case. NOTE: • Use the round bar with diameter of 20 — 21 mm (0.79 — 0.83 in). • By pushing the flange surface (stamp mark side), press it into the transfer case to remove.

MT-02110

6MT-51

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Shift Link Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

13) Remove the roll bearing from the transfer case.

B: INSTALLATION

NOTE: Use the round bar with diameter of 22 — 23 mm (0.87 — 0.91 in).

1) Install the plunger and check ball spring to transmission cover. NOTE: Use a new seal ring.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

(C) (D)

(A) (B)

MT-02129

(E)

14) Remove the plunger and check ball spring from transmission cover. MT-01922

(A) (B) (C) (D) (E)

(C) (D)

(A) (B)

(E)

Plunger Checking ball spring Transmission cover Seal ring Seal bolt

2) Install the needle bearing to the transfer case. MT-01922

(A) (B) (C) (D) (E)

Plunger Checking ball spring Transmission cover Seal ring Seal bolt

NOTE: • Use the round bar with diameter of 20 — 21 mm (0.79 — 0.83 in). • Press in by pushing the flange surface (stamp mark side).

Press-fit depth of needle bearing: A: –8.5 mm (–0.33 in) from the end of transfer case B: –0.2 mm (–0.01 in) from the end of transfer case A

B

MT-02109

3) Install the roll bearing to the transfer case. NOTE: Use the round bar with diameter of 22 — 23 mm (0.87 — 0.91 in).

6MT-52

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Shift Link Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

Press-fit depth of roll bearing: A: 5.1 mm (0.20 in) from the finished surface of transfer case B: Align with the end of transfer case.

NOTE: Use new spring pin. ST 398791700 SPRING PIN REMOVER 2

(B)

B

ST

A

(C) (A) MT-01906

MT-02126

(A) Shifter arm (B) Selector arm (C) Spring pin

4) Using the ST, install the oil seal to the transfer case. NOTE: • Use a new oil seal. • The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for installing the shifter arm No. 2. • Apply transmission gear oil to the oil seal lips.

6) Install the shifter arm No. 2, washers and thrust bearing to transfer case. (B) (C) (B)

Press-fit depth of oil seal: –1.0 mm (–0.04 in) from the end of transfer case ST 18657AA000 INSTALLER

(A)

ST

MT-01905

(A) Shifter arm No. 2 (B) Washer (C) Thrust bearing

7) Install the shifter arm collar and neutral set spring to transfer case. MT-02008

5) Insert the shifter arm into selector arm, then fix with a spring pin using the ST.

Tightening torque: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

MT-01907

6MT-53

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Shift Link Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

8) Install the selector arm No. 2 to neutral set spring.

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

(A)

(B)

MT-01908 MT-01982

(A) Selector arm No. 2 (B) Neutral set spring

12) Install the transmission cover to transfer case.

9) Insert the selector lever COMPL into selector arm No. 2, then fix with a spring pin using the ST.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

NOTE: Use new spring pin. ST 398791700 SPRING PIN REMOVER 2

(A)

ST

(A) (C)

(B) MT-01900

(A) Transmission cover

13) Install the extension assembly to the transfer case. 14) Install the transfer case and the extension case assembly. 15) Install the back-up light switch neutral position switch. 16) Install the manual transmission assembly to the vehicle.

MT-01909

(A) Selector lever COMPL (B) Selector arm No. 2 (C) Spring pin

10) Insert a new straight pin. (B)

(A)

MT-01901

(A) Selector lever COMPL (B) STRAIGHT PIN

11) Apply a proper amount of liquid gasket to the transmission cover mating surface.

6MT-54

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Transmission Case MANUAL TRANSMISSION AND DIFFERENTIAL

14.Transmission Case

NOTE: Use a hammer handle, etc. to remove if too tight.

A: REMOVAL

(A)

1) Remove the manual transmission assembly from the vehicle. 2) Remove the clutch release lever. 3) Remove the transfer case together with the extension case assembly. 4) Remove the bearing mounting bolt.

(B)

MT-01877

(A) Main shaft ASSY for single-range (B) Drive pinion shaft ASSY

8) Remove the main shaft assembly for singlerange. 9) Remove the front differential assembly. NOTE: • Do not confuse the right and left roller bearing outer races. • Be careful not to damage the oil seal of retainer.

MT-01846

5) Remove the main shaft rear plate. (A)

MT-00162

B: INSTALLATION

MT-01847

(A) Main shaft rear plate

6) Separate the transmission case into the right and left cases by loosening the coupling bolts and nuts.

1) Wipe off grease, oil and dust on the mating surfaces of transmission cases with cleaning solvent. 2) Install the front differential assembly. 3) Install the main shaft assembly for single-range. Install the transmission case knock pin into the knock pin hole of needle bearing. 4) Install the drive pinion shaft assembly. Install the transmission case knock pin into the roller bearing knock pin hole. 5) Apply liquid gasket, then join the right side and left side of the case together.

MT-02045

7) Remove the drive pinion shaft assembly from the left side of the transmission case.

6MT-55

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Transmission Case MANUAL TRANSMISSION AND DIFFERENTIAL

Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent

NOTE: Attach the ST on drive pinion assembly. ST 18667AA020 HOLDER

ST

MT-01987

MT-01878

6) With brackets and clips as shown in the figure, tighten the seventeen bolts. NOTE: Match the cases together so that the drive pinion shim and input shaft holder shims are not caught between the cases.

Tightening torque: 8 mm bolt 25 N·m (2.5 kgf-m, 18.4 ft-lb) 10 mm bolt 40 N·m (4.1 kgf-m, 29.5 ft-lb) (16) (9)

(5)

(17)

(7)

(11)

9) Place the transmission with the left side of case facing downward, and put ST1 on bearing cup. 10) Screw the retainer assembly from the bottom into left case using ST2. Fit the ST3 on transmission main shaft. Shift the gear into 4th or 5th, and turn the shaft several times. Screw in the retainer while rotating the ST3 until a slight resistance is felt on ST2. This is the contact point of the hypoid gear and the drive pinion shaft. Repeat the above sequence several times to ensure the contact point. ST1 399780104 WEIGHT ST2 18630AA010 WRENCH COMPL RETAINER ST3 499927100 HANDLE

(13)

ST1 (1)

(3)

ST2

(2)

ST3

(15) (4)

(14) (10) (6)

(8)

(12)

MT-00172

7) Tighten the taper roller bearing mounting bolts.

Tightening torque: 30 N·m (3.1 kgf-m, 22.1 ft-lb)

MT-02042

11) Remove the weight, and screw in the retainer without the O-ring on the upper side, and stop at the point where a slight resistance is felt.

MT-01846

8) Perform backlash adjustment of the hypoid gear and preload measurement of the roller bearing.

6MT-56

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Transmission Case MANUAL TRANSMISSION AND DIFFERENTIAL

NOTE: In this condition, the backlash between hypoid gear and drive pinion shaft is zero. ST 18630AA010 WRENCH COMPL RETAINER

Tightening torque: T: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

ST

T MT-00177

MT-02041

12) Loosen the retainer on the lower side by 3 notches, and turn the retainer on the upper side by the same amount in order to apply backlash. 13) Rotate the retainer of the upper side additionally by 1 notch in order to apply preload on taper roller bearing. 14) Temporarily attach both the upper and lower lock plates, and put marks both the retainer and lock plate for later readjustment. NOTE: When it is difficult to attach the lock plate, turn over the lock plate and attach. 15) Turn the transmission main shaft several times while tapping around the retainer lightly with plastic hammer. 16) Inspect and adjust backlash and tooth contact of the hypoid gear. 17) After checking the tooth contact of the hypoid gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit the Oring into the groove and tighten the retainer into the position before it was loosened. Install the lock plate.

18) Select a main shaft rear plate. 19) Install the clutch release lever and bearing.

20) Install the transfer case together with the extension case assembly. 21) Install the manual transmission assembly to the vehicle.

C: INSPECTION Check the transmission case for cracks, damage, or oil leaks.

NOTE: • When loosening the retainer, record the number of the turns made. • Perform this for both upper and lower retainers. • Use new O-rings.

6MT-57

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Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL

15.Main Shaft Assembly for Single-Range

NOTE: Align the end face of the seal with surface (A) when installing the oil seal.

A: REMOVAL 1) Remove the manual transmission assembly from the vehicle. 2) Remove the transfer case together with the extension case assembly. 3) Remove the transmission case. 4) Remove the drive pinion shaft assembly. 5) Remove the main shaft assembly for singlerange.

B: INSTALLATION 1) Install the needle bearing and oil seal to the front of the transmission single-range main shaft assembly. NOTE: • Wrap the clutch splined section with vinyl tape to prevent damage to the oil seal. • Apply NICHIMOLY N-130 to the sealing lip of the oil seal. • Use a new oil seal. 2) Rotate the reverse idler sub gear by two teeth from free status in the direction of the arrow to make it engage with the reverse gear of the main shaft and install the main shaft assembly. (1) Rotate the reverse idler sub gear to move the alignment mark on the gear by two teeth and secure it with a wire. Set

Free

(A) MT-00185

4) Install the drive pinion shaft assembly. 5) Install the transmission case. 6) Install the transfer case together with the extension case assembly. 7) Install the manual transmission assembly to the vehicle.

C: DISASSEMBLY NOTE: • When replacing the sleeve & hub, replace them as a set. • Do not disassemble the sleeve & hub; the aligning position is pre-matched. • If it is necessary to disassemble, mark the engaging points on the splines beforehand. 1) Put vinyl tape around main shaft spline to protect the oil seal from damage. Then pull out the oil seal and needle bearing by hand. 2) Remove the lock nut from transmission main shaft assembly for single range. NOTE: Flatten the lock nut tab before removing the lock nut. ST1 498937000 TRANSMISSION HOLDER ST2 499987003 SOCKET WRENCH (35)

MT-02092

(2) After installing the main shaft assembly, check that the reverse idler gear and reverse idler sub gear are misaligned by two teeth and remove the wire. CAUTION: Make sure to remove the wire. 3) Install the transmission case knock pin into the knock pin hole of the needle bearing outer race.

6MT-58

ST2

ST1

MT-01879

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3) Remove the 6th drive gear and ball bearing using the ST1, ST2 and a press. ST1 899864100 REMOVER ST2 18722AA000 REMOVER

8) Remove the 3rd drive gear, 4th needle bearing race, 3rd-4th synchronizer hub, inner baulk ring, 3rd synchro cone, outer baulk ring and needle bearing, using the ST1, ST2 and a press. ST1 899864100 REMOVER ST2 899714110 REMOVER

ST1 ST1

ST2

ST2 MT-01923

4) Remove the needle bearing, 6th baulk ring and 5th-6th coupling sleeve. 5) Remove the 5th drive gear, 6th needle bearing race, 5th baulk ring, 5th-6th synchronizer hub and needle bearing, using the ST1, ST2 and a press. ST1 899864100 REMOVER ST2 18722AA000 REMOVER

MT-01926

D: ASSEMBLY 1) When the sleeve & hub assemblies have been disassembled, reassemble by aligning the alignment marks. NOTE: Position the open ends of the spring 120° apart.

ST1 (A)

ST2 MT-01924

6) Shift the 3rd-4th coupling sleeve to 3rd, and remove the 4th drive gear, taper roller bearing and 5th needle bearing race using ST1, ST2 and a press. ST1 899864100 REMOVER ST2 899714110 REMOVER ST1

(B) MT-01990

(A) 3rd-4th hub ASSY (B) 3rd gear side

2) Install the needle bearing, 3rd drive gear, outer baulk ring, 3rd synchro cone, inner baulk ring and 3rd-4th synchronizer hub on the transmission main shaft.

ST2

MT-01925

7) Remove the 4th gear thrust washer, 4th baulk ring, needle bearing and 3rd-4th coupling sleeve.

6MT-59

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Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL

NOTE: Align the groove in baulk ring with the shifting insert. (A)

(D)

• Install the 4th gear thrust washer with the groove side facing the 4th drive gear.

(E)

(A) (B) MT-00193 (B)

(A) (B) (C) (D) (E) (F)

(C)

(F)

MT-01956

(A) Groove (B) Face this surface to the 4th gear side.

3rd needle bearing 3rd drive gear Inner baulk ring 3rd synchro cone Outer baulk ring 3rd-4th synchronizer hub

(C) (E)

(A)

3) Install the 4th needle bearing race onto transmission main shaft using ST1, ST2, ST3 and a press. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER ST3 398177700 INSTALLER

ST2

(B)

(A) (B) (C) (D) (E)

(D)

MT-01973

3rd-4th coupling sleeve 4th baulk ring 4th drive gear Needle bearing 4th gear thrust washer

5) Install the double taper roller bearing into the rear section of transmission main shaft using ST1, ST2 and a press.

ST3

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

(A)

ST1

MT-01936

(A) 4th needle bearing race

4) Install the 3rd-4th coupling sleeve, 4th baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to the transmission main shaft.

NOTE: Install the double taper roller bearing with snap ring side facing the 5th drive gear side. ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER

NOTE: • Align the 4th baulk ring and 3rd-4th synchronizer hub with the key groove. • Install the 3rd-4th coupling sleeve with the groove side facing the 3rd drive gear.

ST2

ST1

MT-01935

6MT-60

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Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL

6) Install the 5th needle bearing race into the rear section of transmission main shaft using ST1, ST2 and a press.

(C)

(B)

(A)

(D)

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER MT-01957

ST2

(A) (B) (C) (D)

(A)

5th-6th synchronizer hub 5th baulk ring 5th drive gear 5th needle bearing (cage: black)

ST1

8) Install the 6th needle bearing race onto transmission main shaft using ST1, ST2 and a press.

MT-01934

(A) 5th needle bearing race

7) Install the needle bearing, 5th drive gear, 5th baulk ring, and 5th-6th synchronizer hub on the transmission main shaft.

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER

NOTE: • Align the protruded section of 5th baulk ring with concave section of 5th-6th synchronizer hub. • Install the 5th-6th synchronizer hub with the groove side facing the 5th drive gear.

ST2

(A)

ST1 (A) MT-01927

(A) 6th needle bearing race

(C)

(B) MT-01941

9) Install the 5th-6th coupling sleeve, 6th baulk ring, 6th drive gear and needle bearing on the transmission main shaft.

(A) 5th-6th synchronizer hub (B) 5th baulk ring (C) 5th drive gear

6MT-61

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Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL

NOTE: Install the 5th-6th coupling sleeve with the short flange side facing the 5th drive gear.

NOTE: Install the ball bearing with the side which does not have lock nut mounting dent facing 6th drive gear. ST1 899714110 REMOVER ST2 899754112 PRESS

(C)

ST2

(A)

(A)

(D)

ST1

(B) MT-01942

(A) (B) (C) (D)

6th baulk ring 5th-6th coupling sleeve 5th-6th shifting insert key Face this side to 5th gear (short flange side)

MT-01928

(A) Ball bearing

11) Tighten the lock nuts to the specified torque using ST1 and ST2.

(C)

NOTE: Lock nuts and lock washers must be replaced with new parts.

(A) (B) (D)

(E)

Tightening torque: 160 N·m (16.3 kgf-m, 118.0 ft-lb) ST1 499987003 SOCKET WRENCH (35) ST2 498937000 TRANSMISSION HOLDER MT-02077

(A) (B) (C) (D) (E)

ST2

5th-6th coupling sleeve 6th baulk ring 6th drive gear 5th needle bearing (cage: black) 6th needle bearing (cage: silver)

ST1

10) Install the ball bearing onto transmission main shaft using ST2 and a press. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

MT-01879

12) Crimp lock nuts in two locations after tightening.

E: INSPECTION Disassembled parts should be washed clean first with cleaning solvent and then inspected carefully. 1) Bearing Replace the bearings in the following cases. • When the bearing balls, outer races and inner races are broken or rusty. • When the bearing is worn. • When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication. • When bearing has other defects. 2) Bushing (each gear) Replace the bushing in following cases.

6MT-62

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Main Shaft Assembly for Single-Range MANUAL TRANSMISSION AND DIFFERENTIAL

• When the sliding surface is damaged or abnormally worn. • When the inner wall is abnormally worn. 3) Gear Replace gears in the following cases. • Replace the gear with new part if its tooth surfaces are broken, damaged or excessively worn. • Correct or replace if the cone that contacts the baulk ring is rough or damaged. • Repair or replace if the inner surface or end face is damaged. 4) Baulk ring Replace the baulk ring in the following cases. • When the inner surface or end face is damaged. • When the ring inner surface is abnormally or partially worn down. • When the contact surface of the synchronizer ring insert section is cracked or abnormally worn. • If the gap between the end faces of the ring and the gear splined part is excessively small, check the clearance (A) while pressing the ring against the cone.

8) Gearshift mechanism Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.

F: ADJUSTMENT Selection of main shaft rear plate: Using the ST, measure the protrusion amount (A) of ball bearing from transmission main case surface, and select a suitable plate in the following table. NOTE: Before measuring, tap the end of main shaft with a plastic hammer lightly in order to make the clearance zero between the main case surface and moving flange of bearing. ST 498147001 DEPTH GAUGE

Clearance (A): 0.5 mm (0.020 in) or more (A)

Dimension (A) mm (in) 4.00 — 4.13 (0.1575 — 0.1626) 3.87 — 4.00 (0.1524 — 0.1575)

Part number

Mark

32294AA041

1

32294AA051

2

(A)

MT-01674

5) Shifting insert key Replace the insert key if deformed, excessively worn or defective in any way.

MT-01213

6) Oil seal Replace the oil seal if the lip is deformed, hardened, worn or defective in any way. 7) O-ring Replace the O-ring if the sealing face is deformed, hardened, damaged, worn or defective in any way.

6MT-63

MT-02125

(A) Measured value

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Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

16.Drive Pinion Shaft Assembly A: REMOVAL 1) Remove the manual transmission assembly from the vehicle. 2) Remove the transfer case together with the extension case assembly. 3) Remove the transmission case. 4) Remove the drive pinion shaft assembly.

NOTE: • Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level. • Tighten the two bolts. ST 499917500 DRIVE PINION GAUGE ASSY (A)

NOTE: Use a hammer handle, etc. to remove if too tight. (B)

ST

(A) (B)

MT-00242

(A) Plate (B) Scale

5) Position the ST by inserting the knock pin of ST into the knock hole of transmission case. ST 499917500 DRIVE PINION GAUGE ASSY 6) Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion. ST 499917500 DRIVE PINION GAUGE ASSY

MT-01877

(A) Main shaft ASSY for single-range (B) Drive pinion shaft ASSY

B: INSTALLATION 1) Remove the front differential assembly. 2) Hypoid gear set match mark/No.: The number (A) on top of the drive pinion, and the number on the hypoid driven gear are set numbers for the two gears. Use a pair having the same numbers. The figure (B) below shows a number for shim adjustment. If no number is shown, the value is zero.

ST

(A)

(A)

MT-01880

(A) Adjust the clearance to zero without shim. +0

.1

(A)

(B) MT-00990

(A) Set number (B) Number for shim adjustment

3) Place the drive pinion shaft assembly on transmission main case RH without shim and tighten the bearing mounting bolts. 4) Check and adjust the ST.

7) The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the ST. (Add if the number on drive pinion is prefixed by +, and subtract if the number is prefixed by –.) ST 499917500 DRIVE PINION GAUGE ASSY 8) Select one to three shims in the following table for the value determined as described above, and take the shim(s) which thickness is closest to the said value.

6MT-64

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Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

NOTE: During installation, be careful to set the cut on the shim facing toward the shifter fork & rod. Part number 32295AA031 32295AA041 32295AA051 32295AA061 32295AA071 32295AA081 32295AA091 32295AA101

Drive pinion shim Thickness mm (in) 0.150 (0.0059) 0.175 (0.0069) 0.200 (0.0079) 0.225 (0.0089) 0.250 (0.0098) 0.275 (0.0108) 0.300 (0.0118) 0.500 (0.0197)

9) Install the front differential assembly. 10) Set the transmission main shaft assembly for single range and drive pinion shaft assembly in position. 11) Install the transmission case. 12) Install the transfer case together with the extension case assembly. 13) Install the manual transmission assembly to the vehicle.

C: DISASSEMBLY NOTE: • Attach a cloth to the end of driven shaft (on the frictional side of the thrust needle bearing) to prevent damage during disassembly or reassembly. • If necessary, use a new gear & hub assembly as a set, when replacing the gear or hub. Because these must engage at the specified point, avoid disassembly as much as possible. If it must be disassembled, mark the engaging point on the spline beforehand. 1) Flatten the tab of the lock nut. Remove the lock nut with ST1, ST2 and ST3. ST1 18680AA020 HOLDER ST2 18667AA020 HOLDER ST3 18662AA010 SOCKET WRENCH (27)

ST3 ST1

ST2

MT-01881

2) Draw out the drive pinion from driven shaft. Remove the differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust bearing, needle bearing and drive pinion collar. (G) (H)

(A) (B) (D)

(C)

(E) (F)

(A) (B) (C) (D) (E) (F) (G) (H)

MT-02018

Differential bevel gear sleeve Adjusting washer No. 1 (25 × 36 × t) Thrust bearing (25 × 36 × 2) Adjusting washer No. 2 (25 × 36 × t) Needle bearing (25 × 30 × 20) Drive pinion collar Needle bearing (30 × 37 × 23) Thrust bearing (33 × 50 × 3)

3) Remove the roller bearing and washer using ST and a press.

6MT-65

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NOTE: Do not reuse the roller bearing. ST 498077000 REMOVER

6) Remove the taper roller bearing and 3rd-4th driven gear using ST1, ST2 and a press. ST1 899754112 PRESS ST2 899714110 REMOVER

ST1

ST ST2

MT-01943

4) Flatten the tab of the lock nut. Remove the lock nut using ST1 and ST2. ST1 499987300 SOCKET WRENCH (50) ST2 18680AA020 HOLDER ST2 ST1

MT-01945

7) Remove the key. 8) Remove the 2nd driven gear, inner baulk ring, synchro cone, outer baulk ring and 1st-2nd coupling sleeve. 9) Remove the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, 2nd gear bushing and 1st-2nd synchronizer hub using ST and a press. ST 18762AA000 COMPRESSOR SPECIAL TOOL

MT-01882

ST

5) Remove the ball bearing, 6th driven gear and drive pinion spacer using the ST1, ST2 and a press. ST1 899754112 PRESS ST2 899714110 REMOVER MT-01946

ST1

ST2

MT-01944

6MT-66

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Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

D: ASSEMBLY 1) Install the sleeve and the gear & hub assembly by matching the alignment marks. NOTE: • Position the open ends of the spring 120° apart. • Use the new gear & hub assembly, if replacing the gear or hub.

NOTE: • Attach a cloth to the end of the driven shaft to prevent damage. • When press fitting, align the oil holes of the shaft and bushing ST 18654AA000 INSTALLER

ST

(A)

(A)

MT-01947

(B)

(A) 2nd driven gear bushing

MT-01964

4) Attach the 1st-2nd coupling sleeve and 1st-2nd shifting insert key to the driven shaft.

(A) 1st-2nd sleeve & hub ASSY (B) 1st gear side

2) Install the 1st driven gear, inner baulk ring, synchro cone and outer baulk ring and 1st-2nd synchronizer hub onto driven shaft. NOTE: • Take care to install the gear & hub assembly in proper direction. • Align the baulk ring and gear & hub assembly with the key groove.

NOTE: • Install the 1st-2nd coupling sleeve with the long flange side facing the 1st driven gear. • Install the 1st-2nd shifting insert keys at 120° interval positions. (B)

(B)

(A) (D)

(A)

(B) MT-01997

(B)

(C)

(A) 1st-2nd coupling sleeve (B) 1st-2nd shifting insert key (three positions)

(E) MT-01959

(A) (B) (C) (D) (E)

1st driven gear Inner baulk ring Synchro cone Outer baulk ring 1st-2nd synchronizer hub

3) Install the 2nd driven gear bushing onto driven shaft using ST and a press. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

6MT-67

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5) Install the outer baulk ring, synchro cone, inner baulk ring and 2nd driven gear to driven shaft. (C)

(B)

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST 499277200 INSTALLER

ST

(A) MT-01998

(A) Outer baulk ring (B) Synchro cone (C) Inner baulk ring

MT-01949

8) Install the 5th driven gear onto driven shaft using ST and a press. (E) (D)

CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

(A)

NOTE: Install the 5th driven gear with the groove side facing the 6th driven gear. ST 499277200 INSTALLER (B)

(C) ST

MT-01960

(A) (B) (C) (D) (E)

2nd driven gear Inner baulk ring Synchro cone Outer baulk ring 1st-2nd coupling sleeve

(A)

MT-01950

6) After installing key on driven shaft, install the 3rd-4th driven gear using an ST and a press. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Align the groove in baulk ring with the insert. ST 499277200 INSTALLER

(A) Install with the groove side facing the 6th driven gear.

9) Install the drive pinion spacer to driven shaft, then install the 6th driven gear to driven shaft using the ST and a press. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST

MT-01948

7) Install a set of roller bearings onto the driven shaft using ST and a press.

6MT-68

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Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

NOTE: Install the 6th driven gear with the stepped side facing the 5th driven gear. ST 499277200 INSTALLER

NOTE: • Crimp the locknut in 2 locations. • Using a spring scale, check that starting torque of the roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.34 lbf).

ST

(A) MT-01951 MT-01953

(A) Install with the stepped side facing the 5th driven gear.

12) Install the roller bearing onto drive pinion.

10) Install the ball bearing onto driven shaft using ST and a press. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST 499277200 INSTALLER

NOTE: When installing the roller bearing, note its directions (front and rear) because the knock pin hole of outer race is offset. (A)

ST

(B)

(A) Roller bearing (B) Knock pin hole

MT-01952

11) Tighten the lock nuts to the specified torque using ST1 and ST2. NOTE: Use a new lock nut.

Tightening torque: 440 N·m (44.9 kgf-m, 324.5 ft-lb) ST1 499987300 SOCKET WRENCH (50) ST2 18680AA020 HOLDER

MT-01965

13) Install the washer using ST1, ST2 and a press. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 499277100 BUSHING 1-2 INSTALLER ST2 499277200 INSTALLER

ST2

ST2 ST1

ST1 (A)

MT-01954

(A) Washer

MT-01883

6MT-69

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Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

14) Install the thrust bearing and needle bearing. Install the driven shaft assembly.

MT-01955

15) Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order.

E: INSPECTION Disassembled parts should be washed clean first with cleaning solvent and then inspected carefully. 1) Bearing Replace the bearings in the following cases. • When the bearing balls, outer races and inner races are broken or rusty. • When the bearing is worn. • When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication. • The ball bearing on the rear side of the drive pinion shaft should be checked for smooth rotation before the drive pinion assembly is disassembled. In this case, because a preload is working on the bearing, its rotation feels like it is slightly dragging unlike other bearings.

(A) (B) (A)

(B)

(C) (D) (E) (F) (G) (H)

MT-01884

MT-02078

(A) (B) (C) (D) (E) (F) (G) (H)

(A) Drive pinion shaft (B) Ball bearing

Driven shaft Drive pinion shaft Drive pinion collar Needle bearing (25 × 30 × 20) Adjusting washer No. 2 (25 × 36 × t) Thrust bearing (25 × 36 × 2) Adjusting washer No. 1 (25 × 36 × t) Differential bevel gear sleeve

16) Adjust the thrust bearing preload.

• When bearing has other defects. 2) Bushing (each gear) Replace the bushing in following cases. • When the sliding surface is damaged or abnormally worn. • When the inner wall is abnormally worn. 3) Gear Replace the bearings in the following cases. • Replace the gear with new part if its tooth surfaces are broken, damaged or excessively worn. • Correct or replace if the cone that contacts the baulk ring is rough or damaged. • Repair or replace if the inner surface or end face is damaged. 4) Baulk ring Replace the rings in the following cases. • When the inner surface or end face are damaged. • When the ring inner surface is abnormally or partially worn down. • If the gap between the end faces of the ring and the gear splined part is excessively small, check the clearance (A) while pressing the ring against the cone.

6MT-70

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Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

F: ADJUSTMENT

Clearance (A): 0.5 mm (0.020 in) or more

1. THRUST BEARING PRELOAD (A)

1) Select a suitable adjusting washer No. 1 so that dimension (H) will be zero in a visual check. Position the washer (20 × 31 × 4) and lock washer (20 × 31 × 2.3) and attach the lock nut (20 × 11).

MT-01674

• When the contact surface of the synchronizer ring insert section is scratched or abnormally worn. 5) Shifting insert key Replace the shifting insert key if deformed, excessively worn or defective in any way.

(H)

MT-01213

MT-02079

6) Oil seal Replace the oil seal if the lip is deformed, hardened, worn or defective in any way. 7) O-ring Replace the O-ring if the sealing face is deformed, hardened, damaged, worn or defective in any way.

2) Using the ST1, ST2 and ST3, tighten the lock nut to the specified torque. NOTE: Use new lock nuts and lock washers.

Tightening torque: 126 N·m (12.8 kgf-m, 92.9 ft-lb) ST1 18680AA020 HOLDER ST2 18667AA020 HOLDER ST3 18662AA010 SOCKET (27)

ST3

ST1 ST2

MT-01885

3) After removing the ST2 used in step 2), measure the starting torque using torque driver.

6MT-71

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Drive Pinion Shaft Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

Starting torque: 0.3 — 0.8 N·m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ftlb) ST1 18680AA020 HOLDER ST3 18662AA010 SOCKET (27)

5) If the specified starting torque cannot be obtained by the selection of washer No. 1, select adjusting washer No. 2 from the list below. Repeat steps 1) through 4) to adjust starting torque.

ST3

(A) (B) ST1

MT-01992 MT-01886

(A) Adjusting washer No. 1 (B) Adjusting washer No. 2

4) If the starting torque is not within the specified limit, select new adjusting washer No. 1 and recheck starting torque.

Starting torque

Dimension H

Low High

Small Large

Adjusting washer No. 2 Part number Thickness mm (in) 803025070 2.850 (0.1122) 803025074 3.000 (0.1181) 803025078 3.150 (0.1240)

(A) (B) MT-01992

(A) Adjusting washer No. 1 (B) Adjusting washer No. 2

Adjusting washer No. 2 Select thicker one. Select thinner one.

6) Recheck that the starting torque is within the specified range, then crimp the lock nut at four positions.

Adjusting washer No. 1 Part number Thickness mm (in) 803025071 2.925 (0.1152) 803025072 2.950 (0.1161) 803025073 2.975 (0.1171) 803025074 3.000 (0.1181) 803025075 3.025 (0.1191) 803025076 3.050 (0.1201) 803025077 3.075 (0.1211)

6MT-72

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Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

17.Front Differential Assembly

B: INSTALLATION

A: REMOVAL

1) Install the differential side retainers using ST. ST 18658AA020 WRENCH COMPL RETAINER 2) Install the bearing outer race to the transmission case. 3) Install the front differential assembly.

1) Remove the manual transmission assembly from the vehicle. 2) Remove the transfer case together with the extension case assembly. 3) Remove the transmission case. 4) Remove the drive pinion shaft assembly. 5) Remove the main shaft assembly for singlerange. 6) Remove the front differential assembly. NOTE: • Do not confuse the right and left roller bearing outer races. • Be careful not to damage the oil seal of retainer.

MT-00162

7) Remove the differential side retainers using ST. ST 18658AA020 WRENCH COMPL RETAINER

NOTE: Be careful not to fold the sealing lip of oil seal.

MT-00162

4) Install the main shaft assembly for single-range.

5) Install the drive pinion shaft assembly. 6) Install the transmission case. 7) Install the transfer case together with the extension case assembly. 8) Install the manual transmission assembly to the vehicle.

ST

MT-02041

8) Remove the bearing outer race from the transmission case. ST 398527700 PULLER ASSY

6MT-73

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Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY

3) Pull out the pinion shaft, and remove the differential bevel pinion, differential bevel gear and washer.

1. DIFFERENTIAL CASE ASSY 1) Loosen the twelve bolts and remove hypoid driven gear.

(B)

(D)

(C) (A)

(C)

(D) (B)

(A)

MT-00277

(A) (B) (C) (D)

Pinion shaft Differential bevel pinion Differential bevel gear Washer

4) Using the ST, remove the roller bearing. ST 899524100 PULLER SET

MT-00275

(A) Hypoid driven gear

ST

2) Drive out the straight pin from differential assembly toward hypoid driven gear side. ST 899904100 REMOVER

MT-00278

2. SIDE RETAINER 1) Remove the O-ring. ST

MT-00276

MT-00279

2) Remove the oil seal. NOTE: • Remove it by using flat tip screwdriver.

6MT-74

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Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

• Do not reuse the oil seal. Replace the oil seal with a new part.

Standard backlash 0.13 — 0.18 mm (0.0051 — 0.0071 in) ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE

ST2

MT-01445

ST1

D: ASSEMBLY

MT-00285

1. DIFFERENTIAL CASE ASSY 1) Install the differential bevel gear and differential bevel pinion together with washer, and insert the pinion shaft. NOTE: Face the chamfered side of washer toward gear.

3) Align the pinion shaft and differential case with each hole, and drive the straight pin into the holes from the hypoid driven gear using the ST. NOTE: Use a new straight pin. ST 899904100 REMOVER

(A) (C)

(B)

(A) (B) (C) MT-00286

MT-00284

(A) Pinion shaft (B) Differential case (C) Straight pin

(A) Differential bevel pinion (B) Differential bevel gear (C) Pinion shaft

2) Measure the backlash between the differential bevel gear and differential bevel pinion. If backlash is not within specified value, install a suitable washer to adjust.

4) Install the roller bearing to differential case. CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Be sure the pinion gear teeth contacts adjacent gear teeth during measurement.

6MT-75

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Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

NOTE: Be careful because the roller bearing outer races are used as a set. ST1 499277100 BUSHING 1-2 INSTALLER ST2 398497701 ADAPTER

• Check the identification marks (L, R) during installation not to mix up the oil seal RH and LH. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER

ST1

ST

MT-00289

ST2

MT-00287

2) Install the O-ring.

5) Install the hypoid driven gear to the differential case using twelve bolts.

Tightening torque: T: 62 N·m (6.3 kgf-m, 45.7 ft-lb)

NOTE: • Use new O-rings. • Do not stretch or damage the O-ring.

(A)

T (B)

MT-00279 MT-00993

E: INSPECTION

(A) Hypoid driven gear (B) Differential case

2. SIDE RETAINER 1) Using the ST, install the differential side retainer oil seal by lightly tapping with a plastic hammer. NOTE: • Use a new oil seal. • Apply transmission gear oil to the oil seal lips, and install the oil seal while being careful not to deform the lip.

Repair or replace the differential gear in the following cases: • When the hypoid drive gear and drive pinion shaft tooth surfaces are damaged, excessively worn, or seized. • When the roller bearing on the drive pinion shaft has a worn or damaged roller path. • When there is damage, wear or seizure of the differential bevel pinion, differential bevel gear, washer, pinion shaft or straight pin.

6MT-76

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Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

• When the differential case sliding surfaces are worn or damaged.

Standard backlash 0.13 — 0.18 mm (0.0051 — 0.0071 in) ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE

(A) (G) (E)

ST2

(F) (F) (E)

(H)

(B)

(C)

ST1

(G)

MT-00285 (D)

(I)

2. HYPOID GEAR BACKLASH 1) Set the ST1, ST2 and ST3. Insert the needle through transmission oil drain plug hole so that the needle comes in contact with the tooth surface on the right corner, and check the backlash. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE ST3 498255400 PLATE 2) Secure the drive pinion shaft using the ST, install SUBARU genuine axle shafts to both sides, rotate in the both directions so that the gauge contacts the tooth surface, and read the dial gauge.

(H) MT-01910

(A) (B) (C) (D) (E) (F) (G) (H) (I)

Drive pinion shaft Hypoid driven gear Pinion shaft Straight pin Washer Differential bevel gear Differential bevel pinion Roller bearing Differential case

NOTE: If the backlash is outside the specified range, adjust it by turning the side retainer in the right side case.

Backlash 0.13 — 0.18 mm (0.0051 — 0.0071 in) ST 18667AA020 HOLDER Part No. 38415AA100 Axle shaft

1. BEVEL PINION GEAR BACKLASH Measure the backlash between the differential bevel gear and differential bevel pinion. If backlash is not within specified value, install a suitable washer to adjust.

ST3

ST2

ST1

6MT-77

MT-00293

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Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

3. TOOTH CONTACT OF HYPOID GEAR

2. HYPOID GEAR BACKLASH

Check tooth contact of hypoid gear as follows: Apply a thin uniform coat of red lead on both teeth surfaces on 3 or 4 teeth of the hypoid gear. Move the hypoid gear back and forth by turning the transmission main shaft until a definite contact pattern is developed on the hypoid gear, and judge whether face contact is correct. When the contact pattern is not correct, adjust. • Tooth contact is correct.

Adjust the backlash by turning the side retainer in the RH side case. ST 18658AA020 WRENCH COMPL RETAINER ST

(A)

(D)

(B)

MT-02041

NOTE: Each time side retainer rotates one tooth, backlash changes by 0.05 mm (0.0020 in). (C)

(A) (B) (C) (D)

0.05mm(0.0020 in)

MT-01402

Toe Coast side Heel Drive side

F: ADJUSTMENT MT-00296

1. BEVEL PINION GEAR BACKLASH 1) Disassemble the front differential assembly.

2) Select a different washer from the table and install. Washer Part number 803038021 803038022 803038023

Thickness mm (in) 0.925 — 0.950 (0.0364 — 0.0374)

3. TOOTH CONTACT OF HYPOID GEAR 1) Adjust until correct teeth contact is obtained. 2) Check tooth contact, and perform the adjustment as follows. • Tooth contact Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.

0.975 — 1.000 (0.0384 — 0.0394) 1.025 — 1.050 (0.0404 — 0.0413)

(A)

3) Adjust until the standard value is obtained.

Backlash: Standard 0.13 — 0.18 mm (0.0051 — 0.0071 in)

(B)

MT-01401

(A) Toe side (B) Heel side

6MT-78

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Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

• Toe contact (inside contact) Check item: Teeth contact area is too small. Contact pattern

• Face contact Check item: Backlash is too large. Contact pattern

AT-00208

AT-00210

Corrective action: Tighten the side retainer to move the driven gear closer to the drive pinion.

Corrective action: Increase thickness of the drive pinion shim according to the procedures for moving the drive pinion shaft away from the driven gear. Also tighten the side retainer to move the driven gear closer to the drive pinion shaft.

MT-01799

• Flank contact Check item: Backlash is too small. Contact pattern

AT-00213

AT-00209

Corrective action: Loosen the side retainer to move the driven gear away from the drive pinion.

MT-01800

6MT-79

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Front Differential Assembly MANUAL TRANSMISSION AND DIFFERENTIAL

• Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern

AT-00211

Corrective action: Reduce thickness of the drive pinion shim according to the procedures for moving the drive pinion shaft closer to driven gear. Also loosen the side retainer to move the driven gear away from the drive pinion.

AT-00212

6MT-80

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Reverse Idler Gear MANUAL TRANSMISSION AND DIFFERENTIAL

18.Reverse Idler Gear A: REMOVAL 1) Remove the manual transmission assembly from the vehicle. 2) Remove the back-up light switch neutral position switch. 3) Remove the transfer case together with the extension case assembly. 4) Remove the transmission case. 5) Remove the drive pinion shaft assembly. 6) Remove the main shaft assembly for singlerange. 7) Remove the front differential assembly. 8) Remove the shifter forks and rods. 9) Remove the snap ring and bolt. Remove the reverse idler gear bushing and drive out the spring pin by tapping it.

NOTE: When driving out the spring pin, rotate the reverse idler gear shaft to prevent it from contacting the case and remove the spring pin into the case inside. (A) (C)

(B)

(D)

MT-02049

(A) (B) (C) (D)

Spring pin Snap ring Reverse idler gear bushing Bolt

10) Pull out the reverse idler gear shaft toward the rear side and remove all parts. NOTE: When pulling out the reverse idler gear shaft, remove the reverse idler gear assembly as a unit while supporting it from the bottom by hand to prevent the parts to scatter in the transmission case. (C)

(B) (A)

(D)

MT-02046

(A) (B) (C) (D)

6MT-81

Oil case guide Washer Reverse idler gear ASSY Reverse idler gear shaft

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Reverse Idler Gear MANUAL TRANSMISSION AND DIFFERENTIAL

B: INSTALLATION NOTE: Rotate the reverse idler sub gear by two teeth from free status in the direction of the arrow to make it engage with the reverse gear of the main shaft and install the main shaft assembly. Free

Set

2) Insert the reverse idler gear bushing into reverse idler gear shaft, install the snap ring and bolt, and then drive in the spring pin to fix. NOTE: • Use new spring pin. • After installation of snap ring, rotate the snap ring 360° to confirm that it is fitted in the groove completely.

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) (A) (C)

MT-02092

1) Insert the reverse idler gear shaft into the transmission case, then install the oil case guide, washer and reverse idler gear assembly as a single unit. NOTE: • Be sure to install the reverse idler gear shaft from rear side. (C)

(B)

(B)

MT-02051

(A) Spring pin (B) Snap ring (C) Reverse idler gear bushing

(A) (D) (A)

(D)

MT-01995

(A) Snap ring (B)

(A)

(C)

MT-02050

(A) (B) (C) (D)

Oil case guide Washer Reverse idler gear ASSY Reverse idler gear shaft

6MT-82

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Reverse Idler Gear MANUAL TRANSMISSION AND DIFFERENTIAL

3) Check and adjust clearance between the reverse idler gear No. 2 and transmission case wall, and the reverse idler gear and reverse idler gear washer. 4) Install the shifter forks and rods. 5) Install the front differential assembly. 6) Install the main shaft assembly for single-range.

7) Install the drive pinion shaft assembly. 8) Install the transmission case. 9) Install the transfer case together with the extension case assembly. 10) Install the back-up light switch neutral position switch. 11) Install the manual transmission assembly to the vehicle.

C: DISASSEMBLY 1) Remove the snap ring from the reverse idler gear assembly.

MT-02055

2) Remove the friction plate, reverse idler sub gear and reverse idler spring.

6MT-83

(B) (D)

(C) (A) MT-02063

(A) (B) (C) (D)

Reverse idler gear Reverse idler sub gear Reverse idler spring Friction plate

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Reverse Idler Gear MANUAL TRANSMISSION AND DIFFERENTIAL

D: ASSEMBLY

E: INSPECTION

1) Insert the reverse idler spring into the holes on reverse idler gear and reverse idler sub gear to install.

1) Move the reverse shifter rod toward the reverse side. Check the clearance between the reverse idler gear and reverse coupling sleeve. If out of specification, select the appropriate reverse shifter fork and adjust.

NOTE: After installing, place alignment marks on the reverse idler gear and reverse idler sub gear.

Clearance (a): 0.50 — 0.85 mm (0.020 — 0.033 in) (B)

(B)

(a)

(A)

(C)

(A)

MT-02065 MT-02038

(A) Reverse idler spring (B) Reverse idler gear (C) Reverse idler sub gear

(A) Reverse idler gear (B) Reverse coupling sleeve

NOTE: Install the reverse idler sub gear with the side with the mark on it facing outside. (A)

2) After installing a suitable reverse shifter fork, shift into neutral. Check the clearance between the reverse idler gear and reverse idler gear washer. If out of specification, select the appropriate reverse idler gear bushing and adjust. NOTE: In clearance check, be sure to insert a thickness gauge vertically.

MT-02064

(A) Side with the mark facing outside

2) Install the friction plate, and then secure with the snap ring.

MT-02055

6MT-84

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Reverse Idler Gear MANUAL TRANSMISSION AND DIFFERENTIAL

F: ADJUSTMENT

Clearance (a): 0.1 — 0.3 mm (0.004 — 0.012 in) (A)

1) Select the appropriate reverse shifter fork from the table below, and adjust until the clearance between the reverse idler gear and reverse coupling sleeve is within specification.

(a)

(B)

Clearance (a): 0.50 — 0.85 mm (0.020 — 0.033 in) (B)

(a)

(A)

MT-02090

(A) Reverse idler gear (B) Reverse idler gear washer

MT-02038

(A) Reverse idler gear (B) Reverse coupling sleeve

Part number 32941AA020

MT-01916

3) Check the reverse idler gear and shaft for damage. Replace if it is damaged.

32941AA030 32941AA040

Reverse shifter fork Mark Content Approaches reverse 2 idler gear by 0.3 mm (0.012 in). No mark Standard Approaches reverse 1 idler gear No. 2 by 0.3 mm (0.012 in).

2) Select the appropriate reverse idler gear bushing from the table below, and adjust until the clearance between the reverse idler gear and reverse idler gear washer is within specification. NOTE: In clearance check, be sure to insert a thickness gauge vertically.

6MT-85

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Reverse Idler Gear MANUAL TRANSMISSION AND DIFFERENTIAL

Clearance (a): 0.1 — 0.3 mm (0.004 — 0.012 in) (A)

(a)

(B)

MT-02090

(A) Reverse idler gear (B) Reverse idler gear washer

MT-01916

Reverse idler gear bushing Part number

Length mm (in)

32289AA010 32289AA020 32289AA030 32289AA040 32289AA050 32289AA060 32289AA070

38.0 (1.496) 38.1 (1.500) 38.2 (1.504) 38.3 (1.508) 38.4 (1.512) 38.5 (1.516) 38.6 (1.520)

Groove for identification No 1 2 3 4 5 6

6MT-86

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Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL

19.Shifter Fork and Rod A: REMOVAL 1) Remove the manual transmission assembly from the vehicle. 2) Remove the back-up light switch neutral position switch. 3) Remove the transfer case together with the extension case assembly. 4) Remove the transmission case. 5) Remove the drive pinion shaft assembly. 6) Remove the main shaft assembly for singlerange. 7) Remove the front differential assembly. 8) Remove the check ball plugs, gasket, check ball springs and check balls.

9) Drive out the spring pins on the 5th-6th shifter fork and reverse shifter fork by tapping with the ST, and remove the 5th-6th shifter fork, reverse shifter fork, 5th-6th fork rod and reverse fork rod. NOTE: Before driving out the spring pin on the reverse shifter fork, position the gear in the reverse position. If the gear is in the neutral position, the spring pin cannot be removed due to small clearance with the transmission case. ST 398791700 SPRING PIN REMOVER 2 (A)

(C) (C)

(D) MT-01918

(A) (B) (C) (D) (E)

(A) (B)

(B)

(E)

(C)

5th-6th shifter fork Reverse shifter fork Spring pin 5th-6th fork rod Reverse fork rod

10) Drive out the spring pin by tapping with the ST, and remove the 3rd-4th shifter fork and fork rod. NOTE: When removing the rod, keep other rods in neutral. ST 398791700 SPRING PIN REMOVER 2

(D)

(A) (C)

(B)

(D) (C) (B) (A) MT-01919

(A) 3rd-4th shifter fork (B) 3rd-4th fork rod (C) Spring pin

MT-02039

(A) (B) (C) (D)

1st-2nd 3rd-4th 5th-6th Rev.

6MT-87

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Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL

11) Drive out the spring pin by tapping with the ST, and remove the 1st-2nd shifter fork and fork rod. ST 398791700 SPRING PIN REMOVER 2

• Check that the positions of interlock plunger is correct. ST 398791700 SPRING PIN REMOVER 2

(A)

(A) (C)

(B)

(B)

(C)

MT-01920

MT-01919

(A) 3rd-4th shifter fork (B) 3rd-4th fork rod (C) Spring pin

(A) 1st-2nd shifter fork (B) 1st-2nd fork rod (C) Spring pin

B: INSTALLATION 1) Install the 1st-2nd fork rod into 1st-2nd shifter fork through the hole on the rear of transmission case. 2) Align the holes in the rod and the fork, and drive the spring pin into these holes using the ST to fix. NOTE: Use new spring pin. ST 398791700 SPRING PIN REMOVER 2

5) Install the 5th-6th fork rod into 5th-6th shifter fork, then insert through the hole on the rear of transmission case. Align the hole of the 5th-6th shifter fork with the hole on the transmission case, then insert the reverse fork rod to install the reverse shifter fork. 6) Align the holes in the rod and the fork, and drive the spring pin into these holes using the ST to fix. NOTE: • Use new spring pin. • Set other rods to neutral. • Check that the positions of interlock plunger is correct. ST 398791700 SPRING PIN REMOVER 2

(A)

(B)

(A)

(C)

(E)

(B)

MT-01920 (C)

(A) 1st-2nd shifter fork (B) 1st-2nd fork rod (C) Spring pin

(C)

MT-01918

3) Attach the 3rd-4th fork rod into 3rd-4th shifter fork through the hole on the rear of transmission case. 4) Align the holes in the rod and the fork, and drive the spring pin into these holes using the ST to fix. NOTE: • Use new spring pin. • Set other rods to neutral.

(D)

(A) (B) (C) (D) (E)

5th-6th shifter fork Reverse shifter fork Spring pin 5th-6th fork rod Reverse fork rod

7) Install the check ball plugs, gaskets, check ball springs and check balls. NOTE: Use a new gasket.

6MT-88

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Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL

C: INSPECTION

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb)

1) Check the fork and rod for damage. Replace if it is damaged. 2) Gearshift mechanism Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way. 3) Inspect the clearance between 2nd driven gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.

(A) (B)

(C)

Clearance (a): 9.4 — 10.0 mm (0.370 — 0.394 in)

(D)

(a)

(A)

(C)

(B)

(D) (C) (B) (A) MT-01975 MT-02039

(A) 1st driven gear (B) Coupling sleeve (C) 2nd driven gear

(A) 1st-2nd (B) 3rd-4th (C) 5th-6th (D) Rev.

Part number

8) Install the front differential assembly. 9) Install the main shaft assembly for single-range.

10) Install the drive pinion shaft assembly. 11) Install the transmission case. 12) Install the transfer case together with the extension case assembly. 13) Install the back-up light switch neutral position switch. 14) Install the manual transmission assembly to the vehicle.

6MT-89

1st-2nd shifter fork Mark

32804AA120

1

32804AA130

No mark

32804AA140

3

Content

Approaches 1st gear by 0.2 mm (0.008 in). Standard Approaches 2nd gear by 0.2 mm (0.008 in)

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Shifter Fork and Rod MANUAL TRANSMISSION AND DIFFERENTIAL

4) Inspect the clearance between the 3rd, 4th drive gear and the coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.

Clearance (b): 9.4 mm (0.370 in) (b)

(A)

(B)

(C)

Clearance (a): 7.4 mm (0.291 in)

(a)

Clearance (b): 9.3 mm (0.366 in) (a)

(b)

(A)

(C)

(B) MT-01977

(A) 5th drive gear (B) Coupling sleeve (C) 6th drive gear

MT-01976

Part number

(A) 3rd drive gear (B) Coupling sleeve (C) 4th drive gear

Part number

3rd-4th shifter fork Mark

32810AA061

1

32810AA071

No mark

32810AA101

3

Content

Approaches 4th gear by 0.2 mm (0.008 in). Standard Approaches 3rd gear by 0.2 mm (0.008 in)

5) Inspect the clearance between 5th, 6th drive gear and coupling sleeve. If any clearance is not within specifications, replace the shifter fork as required.

5th-6th shifter fork Mark

32940AA020

1

32940AA030

No mark

32940AA040

2

Content

Approaches 5th gear by 0.2 mm (0.008 in). Standard Approaches 6th gear by 0.2 mm (0.008 in).

6) Inspect the rod end clearances (A) and (B). If any clearance is not within specifications, replace the rod or fork as required.

Clearance (A): 1st-2nd — 3rd-4th 0.1 — 0.9 mm (0.004 — 0.035 in) Clearance (B): 3rd-4th — 5th-6th 0.2 — 1.0 mm (0.008 — 0.039 in)

Clearance (a): 8.8 mm (0.346 in) (A)

(B)

MT-01974

6MT-90

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General Diagnostic Table MANUAL TRANSMISSION AND DIFFERENTIAL

20.General Diagnostic Table A: INSPECTION 1. MANUAL TRANSMISSION Symptoms 1. Gears are difficult to intermesh. NOTE: The cause for difficulty in shifting gears can be classified into two types: One is a defective gear shift system and the other is defective transmission. However, if the operation is heavy and engagement of the gears is difficult, a defective clutch disengagement may also be responsible. Check whether the clutch is correctly functioning, before checking the gear shift system and transmission. 2. Gear slip-out • Gear slips out when coasting on rough road. • Gear slips out during acceleration.

3. Noise emitted from transmission NOTE: If a noise is heard when the vehicle is parked with its engine idling and if a noise ceases when the clutch is disengaged, it may be considered that the noise is coming from the transmission.

Possible cause (a) Worn, damaged or burred chamfer at internal spline of the sleeve (b) Gear spline wear, damage, dents (c) Worn or scratched bushings (d) Incorrect contact or wear between synchronizer ring and gear cone

(a) Loose engine mounting bolts (b) Worn fork shifter or broken shifter fork rail spring (c) Worn or damaged ball bearing (d) Excessive clearance between splines of synchronizer hub and synchronizer sleeve (e) Synchronizer hub tooth step wear (f) Worn 1st driven gear and driven shaft (g) Worn 2nd driven gear and bushing (h) Worn 3rd drive gear and needle bearing (i) Worn 4th drive gear and needle bearing (j) Worn 5th drive gear and needle bearing (k) Worn 6th drive gear and needle bearing (l) Worn reverse idler gear and needle bearing (a) Insufficient or improper lubrication

Corrective action Replace. Replace. Replace. Repair or replace.

Tighten or replace. Replace. Replace. Replace.

Replace. Replace. Replace. Replace. Replace. Replace. Replace. Replace. Lubricate with recommended oil or replace.

(b) Worn or damaged gears and bearings Replace. NOTE: If the trouble is only wear of the gear teeth surfaces, only a high whirring noise will occur at high speeds, but if any part is broken, rhythmical clicking sounds will be heard even at low speeds.

6MT-91

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General Diagnostic Table MANUAL TRANSMISSION AND DIFFERENTIAL

2. DIFFERENTIAL Symptoms 1. Broken differential (case, gear, bearing, etc.) NOTE: Noise will occur, and eventually the differential will not be able to operate due to broken pieces obstructing the gear revolution.

2. Differential and hypoid gear noises Troubles of the differential and hypoid gear always appear as noise problems. Therefore noise is the first indication of trouble. However, noises from the engine, muffler, tire, exhaust gas, bearing, body, etc. are easily mistaken for the differential noise. Pay special attention to the hypoid gear noise because it is easily confused with other gear noises. There are the following four kinds of noises. • Gear noise when driving: If noise increases as the vehicle speed increases, it may be due to insufficient gear oil, incorrect gear engagement, damaged gears, etc. • Gear noise when coasting: Damaged gears due to misadjusted bearings and incorrect shim adjustment. • Bearing noise when driving or coasting: Cracked, broken or damaged bearings • Noise mainly when turning: Noise from differential side gear, differential pinion or differential pinion shaft, etc.

Possible cause (a) Insufficient or improper oil

(b) Use of vehicle under severe conditions such as excessive load or improper use of the clutch (c) Improper adjustment of taper roller bearing (d) Improper adjustment of the drive pinion and the hypoid driven gear (e) Excessive backlash of a vehicle under severe operating conditions due to worn differential side gear, washer or differential pinion. (f) Loose hypoid driven gear clamping bolts

Corrective action Disassemble the differential and replace broken components. At the same time check other components for any trouble, and replace if necessary. Readjust the preload and backlash of the bearing, and the contact surface of gear. Adjust. Adjust. Add recommended oil to the specified level. Do not use vehicle under severe operating conditions. Tighten.

(a) Insufficient oil

Add recommended oil to the specified level.

(b) Improper adjustment of hypoid driven gear and drive pinion (c) Worn teeth of hypoid driven gear and drive pinion (d) Loose roller bearing

Check the tooth contact.

(e) Distorted hypoid driven gear or differential case (f) Worn washer and differential pinion shaft

6MT-92

Replace as a set. Readjust the bearing preload. Readjust the backlash of the hypoid driven gear to drive pinion, and check the tooth contact. Replace. Replace.

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2015年12月24日 木曜日 午後5時18分

CLUTCH SYSTEM

CL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Page General Description ...................................................................................2 Clutch Disc and Cover .............................................................................11 Flywheel ...................................................................................................14 Release Bearing and Lever ......................................................................15 Operating Cylinder ...................................................................................18 Master Cylinder ........................................................................................20 Clutch Pipe and Hose ..............................................................................22 Clutch Fluid ..............................................................................................24 Clutch Fluid Air Bleeding ..........................................................................25 Clutch Pedal .............................................................................................26 Clutch Switch ...........................................................................................31 General Diagnostic Table .........................................................................33

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General Description CLUTCH SYSTEM

1. General Description A: SPECIFICATION Model Transmission type Type Clutch cover Diaphragm set load Facing material O.D. × I.D. × thickness mm (in) Spline outer diameter Clutch disc Depth of rivet head mm (in)

Deflection limit Clutch release lever ratio Release bearing Clutch pedal Flywheel

Full stroke Free play Type

2.5 L non-turbo

2.5 L turbo 6MT Push type

N (kgf, lbf)

5,688 (580, 1,279) 7,450 (760, 1,675) Woven (Non-asbestos)

Flywheel side

230 × 155 × 3.2 (9.06 × 6.10 × 0.126)

Clutch cover side

230 × 155 × 3.5 (9.06 × 6.10 × 0.138)

mm (in)

25.2 (0.992), (Number of teeth: 24)

Flywheel side Clutch cover side Limit of sinking

1.35 — 1.95 (0.053 — 0.077) 1.65 — 2.25 (0.065 — 0.089) 0.3 (0.012)

mm (in)

0.7 (0.028) at R = 110 (4.33) 1.6 Grease-packed self-aligning

mm (in) mm (in)

130 — 135 (5.12 — 5.31) 135 — 140 (5.31 — 5.51) 4 — 11 (0.16 — 0.43) Flexible

CL-2

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General Description CLUTCH SYSTEM

B: COMPONENT 1. CLUTCH ASSEMBLY

(1) (3) (2)

T2 (5)

T1 (4) (3)

(10) (11)

(2)

(6) (5) (8)

T1

T1

(9)

(7)

CL-00780

(1)

Dust cover

(6)

(2) (3) (4) (5)

Lever spring Pivot Release lever (non-turbo model) Clip (non-turbo model)

(7) (8) (9) (10)

Release bearing (non-turbo model) Release lever (turbo model) Release bearing (turbo model) Clutch cover Clutch disc

CL-3

(11)

Flexible flywheel

Tightening torque:N·m (kgf-m, ft-lb) T1: 16 (1.6, 11.8) T2: 75 (7.6, 55.3)

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General Description CLUTCH SYSTEM

2. CLUTCH PIPE AND HOSE

(10)

T1 T1

(15) T3

(11)

(8)

T1

T3 T4 (6)

(13)

(7) T1

(2)

(3)

T4

(14)

(9)

(17)

T5

(1)

(17)

T3

T4

(21)

(16)

(5)

T2

(12) T3

T3 T5 T4

(2) T3

(4) T2 (19)

(18)

T3

(20)

CL-00782

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Operating cylinder (turbo model) Washer Clutch hose (turbo model) Operating cylinder (non-turbo model) Clutch hose (non-turbo model) Clutch hose bracket Clamp Clutch pipe Connector Reservoir tank bracket

(11) (12) (13) (14)

Reservoir tank Clutch pipe Reservoir tank hose Clutch pipe grommet

(15) (16) (17) (18) (19) (20)

Clamp Clutch pipe Clamp Clutch damper Clutch pipe Master cylinder ASSY

CL-4

(21)

Mass damper

Tightening torque:N·m (kgf-m, ft-lb) T1: 7.5 (0.8, 5.5) T2: T3: T4: T5:

7.8 (0.8, 5.8) 15 (1.5, 11.1) 18 (1.8, 13.3) 37 (3.8, 27.3)

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General Description CLUTCH SYSTEM

3. MASTER CYLINDER

T

(2)

(3)

(1)

CL-00750

(1) (2)

Master cylinder ASSY Clevis pin

(3)

Clip

Tightening torque:N·m (kgf-m, ft-lb) T: 18 (1.8, 13.3)

CL-5

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General Description CLUTCH SYSTEM

4. OPERATING CYLINDER • Non-turbo model

T (6)

(3) (2)

(1)

(4)

(5)

CL-00748

(1) (2) (3)

Push rod Boot Piston

(4) (5) (6)

Piston spring Operating cylinder Bleeder screw

CL-6

Tightening torque:N·m (kgf-m, ft-lb) T: 7.8 (0.8, 5.8)

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General Description CLUTCH SYSTEM

• Turbo model T (6)

(3) (2)

(1)

(4)

(5)

CL-00504

(1) (2) (3)

Push rod Boot Piston

(4) (5) (6)

Piston spring Operating cylinder Bleeder screw

CL-7

Tightening torque:N·m (kgf-m, ft-lb) T: 7.8 (0.8, 5.8)

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General Description CLUTCH SYSTEM

5. CLUTCH PEDAL

(19)

(20)

T3 (17) (21)

(16) (15)

T2 (7)

(18)

(6)

(7)

T2

(5)

T1

(12)

(9) T1 (22)

(9)

(3)

T2

(4) (11)

T2

(23) T3

(7) T1

(6)

T2 (14) (10)

(13)

(7)

(2)

(5) (1) (5) (8) CL-00760

CL-8

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General Description CLUTCH SYSTEM (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Clutch pedal Clutch pedal pad Brake pedal Brake pedal pad STOPPER SPACER Bushing Torsion spring Assist bushing Torsion spring bushing

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)

Clevis pin Snap pin Bushing A Assist spring (turbo model) Clevis pin Master cylinder ASSY Clip Clutch start switch Stop & brake switch Clutch switch

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Use SUBARU genuine fluid, grease etc. or equivalent. Do not mix fluid, grease, etc. of different grades or manufacturers. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Apply grease onto sliding or revolving surfaces before installation. • Before installing O-rings or snap rings, apply sufficient amount of fluid to avoid damage and deformation. • Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise. • Keep fluids away from the vehicle body. If any fluid contacts the vehicle body, immediately flush the area with water.

CL-9

(21) (22) (23)

Pedal bracket Sensor harness Band

Tightening torque:N·m (kgf-m, ft-lb) T1: 8 (0.8, 5.9) T2: 18 (1.8, 13.3) T3: 30 (3.1, 22.1)

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General Description CLUTCH SYSTEM

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 498497100

DESCRIPTION CRANKSHAFT STOPPER

REMARKS Used for stopping rotation of the flywheel.

CLUTCH DISC GUIDE

Used for installing the clutch disc to the flywheel.

ST-498497100

499747100

ST-499747100

2. GENERAL TOOL TOOL NAME Circuit tester Dial gauge DEPTH GAUGE

REMARKS Used for measuring resistance, voltage and ampere. Used for measuring clutch disc run-out. Used for measuring clutch disc wear.

CL-10

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Clutch Disc and Cover CLUTCH SYSTEM

2. Clutch Disc and Cover A: REMOVAL 1) Remove the transmission assembly from vehicle body. 2) Attach the ST to the flywheel. ST 499747100 CLUTCH DISC GUIDE (A)

NOTE: • When installing a clutch cover to the flywheel, position the clutch cover so that the spacing between the unbalance marks (paint mark) on the flywheel and clutch cover is 120° or more apart. (The unbalance mark indicates the direction of residual unbalance.) • Note the front and rear of the clutch disc when installing. • Temporarily tighten the bolts by hand. Each bolt should be tightened to the specified torque in a crisscross order.

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

ST CL-00011

(A) Clutch cover

3) Remove the clutch cover and clutch disc. NOTE: • Take care not to allow oil to touch the clutch disc face. • Do not disassemble the clutch cover or clutch disc.

(A)

B: INSTALLATION

(3)

1) Insert the ST into the clutch disc and attach to the flywheel by inserting the ST end into pilot bearing.

(1)

(5) (6)

NOTE: When installing the clutch disc, be careful to attach in the correct direction. ST 499747100 CLUTCH DISC GUIDE

(2)

(4)

ST CL-00013

(A) Unbalance mark (paint)

3) Remove the ST. 4) Install the transmission assembly. 5) When the clutch disc has been replaced, perform the clutch sensor calibration mode.

(A) ST

CL-00208

(A) Flywheel side

2) Install the clutch cover to the flywheel and tighten the bolts to the specified torque.

NOTE: If necessary, perform the clutch meet position setting.

CL-11

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Clutch Disc and Cover CLUTCH SYSTEM

C: INSPECTION

Limit for deflection: 0.7 mm (0.028 in) at R = 110 mm (4.33 in) ST 499747100 CLUTCH DISC GUIDE

1. CLUTCH DISC 1) Facing wear Measure the depth from the facing surface to the rivet head. Replace if the face is worn locally or worn down to less than the specified value.

ST

Depth to rivet head: Limit of sinking 0.3 mm (0.012 in) NOTE: Do not wash the clutch disc with any type of cleaning fluid.

CL-00016

5) If there is spline wear, loose rivets, failed damper springs, etc., replace the clutch disc.

CL-00014

2) Hardened facing Replace the clutch disc. 3) Oil soakage on facing Replace the clutch disc and inspect the transmission front oil seal, transmission case mating surface, engine rear oil seal and other locations for oil leakage. (A)

CL-00017

(A) Spline (B) Rivet (C) Damper spring

2. CLUTCH COVER NOTE: Visually check the following items without disassembling, and replace or repair if defective. 1) Loose thrust rivet 2) Damaged or worn bearing contact area at the center of diaphragm spring (A) (B)

CL-00015

(A) Clutch facing

4) Deflection on facing If deflection exceeds the specified value at the outer circumference of the facing, replace the clutch disc.

CL-00553

(A) Thrust rivet (B) Diaphragm spring

3) Damaged and worn disc contact surface of the pressure plate 4) Loose strap plate installation area

CL-12

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Clutch Disc and Cover CLUTCH SYSTEM

5) Worn sliding area of diaphragm spring (A)

(B)

CL-00176

(A) Pressure plate (B) Strap plate

CL-13

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Flywheel CLUTCH SYSTEM

3. Flywheel

Tightening torque: 75 N·m (7.6 kgf-m, 55.3 ft-lb)

A: REMOVAL 1) Remove the transmission assembly. 2) Remove the clutch cover and clutch disc. 3) Using the ST, remove the flywheel. ST 498497100 CRANKSHAFT STOPPER

(5)

(1) (7)

(3)

(4)

(8) (2)

(6)

CL-00021

3) Install the clutch disc and cover. 4) Install the transmission assembly.

C: INSPECTION

(A) ST

CL-00019

(A) Flywheel

B: INSTALLATION 1) Temporarily tighten the flywheel, and attach the ST. ST 498497100 CRANKSHAFT STOPPER

CAUTION: Because this bearing is grease-sealed and is a non-lubrication type, do not wash with gasoline or solvents. 1) If there is damage or defectiveness in the facing sliding surface or ring gear, replace the flywheel. (B)

(A) CL-00022 ST

(A) Flywheel (B) Ring gear

CL-00020

2) Tighten the flywheel mounting bolts to the specified torque. NOTE: Tighten the flywheel attachment bolts gradually. Each bolt should be tightened to the specified torque in crisscross order.

2) Smoothness of rotation Rotate the ball bearing while applying pressure in the thrust direction. 3) If noise or excessive play is noted, replace the flywheel.

CL-14

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Release Bearing and Lever CLUTCH SYSTEM

4. Release Bearing and Lever A: REMOVAL 1) Remove the transmission assembly from vehicle body. 2) Remove the two clips from the clutch release lever. (non-turbo model)

6) Remove the lever spring from the pivot with a screwdriver by accessing it through the clutch housing release lever hole. Then remove the release lever and release bearing as a unit. (turbo model) (B)

CAUTION: Be careful not to deform the clips. 3) Remove the release bearing. (non-turbo model) 4) Remove the dust cover.

(A)

(A) CL-00715

(A) Release lever (B) Screwdriver (B)

B: INSTALLATION CL-00714

(A) Release lever (B) Dust cover

5) Remove the lever spring from the pivot with a screwdriver by accessing it through the clutch housing release lever hole. Then remove the release lever. (non-turbo model) (B)

(A)

CL-00715

(A) Release lever (B) Screwdriver

NOTE: Apply the specified grease to lubricate to the following points before installation. • Contact surface of lever and pivot • Contact surface of lever and bearing • Transmission main shaft spline (NICHIMOLY N130) 1) Temporarily assemble the release bearing to the release lever. (turbo model) 2) While pushing the release lever to the pivot and twisting it to both sides, fit the lever spring onto the raised portion of the pivot. (non-turbo model) NOTE: • Apply grease (NICHIMOLY N-130) to the contact point of the release lever and operating cylinder. • Observing from the main case hole, check that the lever spring is installed securely. 3) Install the release bearing by inserting the release lever into the clutch housing release lever hole. Then, fit the lever spring onto the raised portion of the pivot by pushing the release lever to the pivot and twisting it to both sides. (turbo model) 4) Install the release bearing and fasten it with two clips. (non-turbo model)

CL-15

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Release Bearing and Lever CLUTCH SYSTEM

5) Install the dust cover.

• Turbo model

(A) (A)

(B)

CL-00714

CL-00744

(A) Release lever (B) Dust cover

(A) Bearing case

6) Check the bearing for smooth movement by operating the release lever. 7) Install the transmission assembly.

2) While applying force to the bearing in the rotational direction, check the bearing for smooth rotation. • Non-turbo model

C: INSPECTION 1. RELEASE BEARING CAUTION: Because this bearing is grease-sealed and is a non-lubrication type, do not wash with gasoline or solvents when servicing the clutch. 1) Check the bearing for smooth movement by applying force to the bearing in the radial direction.

Radial direction stroke: 1.6 mm (0.063 in) • Non-turbo model

(A)

CL-00160

(A) Bearing case

• Turbo model

(A)

(A) CL-00745 CL-00032

(A) Bearing case

(A) Bearing case

3) Check for wear or damage at the bearing case surface in contact with the lever.

CL-16

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Release Bearing and Lever CLUTCH SYSTEM

2. RELEASE LEVER Check the pivot portion of the lever and the contact area with the release bearing case for wear. • Non-turbo model (A)

(B)

(C)

CL-00034

(A) Release lever (B) Pivot (C) Release bearing

• Turbo model (A)

(B) (C)

CL-00746

(A) Release lever (B) Pivot (C) Release bearing

CL-17

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Operating Cylinder CLUTCH SYSTEM

5. Operating Cylinder

B: INSTALLATION

A: REMOVAL

NOTE: • The illustration shows a representing model. Perform the same procedures for the other models. • Be sure to install the clutch hose with the mark side facing upward. • Be careful not to twist the clutch hose during installation. • Before installing the operating cylinder, apply grease (NICHIMOLY N-130) to the contact point of the release lever and operating cylinder. 1) Install in the reverse order of removal.

NOTE: The illustration shows a representing model. Perform the same procedures for the other models. 1) Remove the collector cover. 2) Remove the air intake boot assembly. (non-turbo model) 3) Remove the intercooler. (turbo model) 4) Disconnect the clutch hose from the operating cylinder. CAUTION: • Cover the hose joint to prevent the clutch fluid from flowing out. • Do not loosen or remove the cap bolts.

Tightening torque: T1: 18 N·m (1.8 kgf-m, 13.3 ft-lb) T2: 37 N·m (3.8 kgf-m, 27.3 ft-lb) T1 T2

(A)

T2 CL-00709

(B) (A) CL-00707

(A) Clutch hose (B) Operating cylinder

5) Remove the operating cylinder from the transmission.

(B) (C) CL-00743

(A) Clutch hose (B) Operating cylinder (C) Mark

CL-00708

2) After bleeding air from the operating cylinder, ensure that the clutch operates properly. 3) When the operating cylinder has been replaced or removed, perform the clutch sensor calibration mode. NOTE: If necessary, perform the clutch meet position setting.

CL-18

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Operating Cylinder CLUTCH SYSTEM

C: DISASSEMBLY NOTE: The illustration shows a representing model. Perform the same procedures for the other models. 1) Remove the boot and push rod.

3) Install push rod to the boot. 4) Install boot and push rod to the operating cylinder.

CL-00716

E: INSPECTION CL-00716

2) Apply compressed air through clutch hose attachment hole. NOTE: Face the piston hole down and place a piece of wood underneath to prevent the piston from popping out. 3) Separate the piston and piston spring.

1) Check that the operating cylinder is not damaged. Replace the operating cylinder if it is damaged. 2) Check the clutch fluid leakage on the operating cylinder or the boot for damage. Replace the operating cylinder if clutch fluid leaks or boot damages are noted.

CL-00717

D: ASSEMBLY NOTE: • The illustration shows a representing model. Perform the same procedures for the other models. • During assembly, apply hydraulic oil to all parts.

Recommended clutch fluid: New FMVSS No. 116 DOT3 1) Install the piston spring onto the piston.

CL-00717

2) Insert piston to the operating cylinder.

CL-19

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Master Cylinder CLUTCH SYSTEM

6. Master Cylinder

9) Remove the master cylinder from the pedal bracket.

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the collector cover. 3) Drain clutch fluid from reservoir tank completely. 4) Remove the instrument panel lower cover. 5) Remove the pedal assembly. 6) Remove the clip and clevis pin, and then separate the push rod of the master cylinder from clutch pedal.

(A)

CL-00755

(A) Master cylinder

B: INSTALLATION

(A)

1) Install the master cylinder to the pedal assembly. (B)

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

(C) CL-00761

(A)

(A) Clevis pin (B) Clip (C) Push rod

7) Disconnect the clutch stroke sensor connector. 8) Remove the clutch pipe from the master cylinder.

CL-00755

(A) Master cylinder

2) Connect the clutch pipes to the master cylinder.

Tightening torque: 15 N·m (1.5 kgf-m, 11.1 ft-lb)

CL-00754

CL-00754

3) Connect the clutch stroke sensor connector. 4) Connect the push rod of the master cylinder to the clutch pedal, and install the clevis pin and clip. CAUTION: Always use a new clevis pin.

CL-20

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Master Cylinder CLUTCH SYSTEM

NOTE: Apply grease to the clevis pin. (A)

(B)

(C) CL-00762

(A) Clevis pin (B) Clip (C) Push rod

5) Install the pedal assembly. 6) Install the instrument panel lower cover. 7) Connect the ground cable to battery. 8) Fill the recommended clutch fluid. 9) After bleeding air from the clutch system, ensure that the clutch operates properly. 10) Install the collector cover. 11) When the clutch master cylinder assembly has been replaced, perform the clutch sensor calibration mode. NOTE: If necessary, perform the clutch meet position setting.

C: INSPECTION If any damage, deformation, wear, swelling, rust or other faults are found on the master cylinder assembly, reservoir tank, clutch damper, clutch pipe and clutch hose, replace the faulty part.

CL-21

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Clutch Pipe and Hose CLUTCH SYSTEM

7. Clutch Pipe and Hose

7) Pull out the clamp, then remove the clutch hose from the clutch bracket.

A: REMOVAL

(C)

1) Disconnect the ground cable from battery. 2) Remove the collector cover. 3) Remove the air intake boot assembly. (non-turbo model) 4) Remove the intercooler. (turbo model) 5) Drain clutch fluid from reservoir tank completely. 6) Disconnect the clutch pipe from the clutch hose and connector. Disconnect the reservoir tank hose from the reservoir tank. CAUTION: Be careful not to spill the clutch fluid. Clutch fluid spilled on the vehicle body will harm the paint surface; if spilled, wash off with water immediately and wipe off. (A)

(C)

(A)

(B) CL-00722

(A) Clamp (B) Clutch hose (C) Clutch bracket

8) Disconnect the clutch hose from operating cylinder. 9) Remove the clutch bracket. 10) Remove the instrument panel lower cover.

11) Remove the pedal assembly. 12) Remove the clutch pipe from the reservoir tank hose, mass damper, clutch damper, master cylinder and clutch pipe grommet.

(A)

(A)

(B) (B) (A)

CL-00763

(A) Clutch pipe (B) Clutch hose (C) Reservoir tank hose

(A)

CL-00764

(A) Clutch pipe (B) Reservoir tank hose

CL-22

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Clutch Pipe and Hose CLUTCH SYSTEM

B: INSTALLATION Install in the reverse order of removal. NOTE: After bleeding air from the clutch fluid, ensure that the clutch operates properly.

Tightening torque: T1: 7.5 N·m (0.8 kgf-m, 5.5 ft-lb) T2: 15 N·m (1.5 kgf-m, 11.1 ft-lb) T3: 18 N·m (1.8 kgf-m, 13.3 ft-lb) T2

(A) T2

Tightening torque: T: 15 N·m (1.5 kgf-m, 11.1 ft-lb) (D) T2

(C)

(C)

(A)

(B)

(A) T3

(A) T

T1 T

(B)

T

(A) CL-00766

(A) Clutch pipe (B) Clamp (C) Clutch hose

T

CL-00765

(A) (B) (C) (D)

Clutch pipe Reservoir tank hose Clutch pipe grommet Clamp

C: INSPECTION Check the clutch pipe, reservoir tank hose and clutch hose for crack, breaks or damage. Check the joint for clutch fluid leakage. If crack, breakage, damage or leakage is found, repair or replace the faulty clutch pipe, reservoir tank hose or clutch hose.

CL-23

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Clutch Fluid CLUTCH SYSTEM

8. Clutch Fluid A: INSPECTION 1) Park the vehicle on a level surface. 2) Check the clutch fluid level using the scale on the outside of the reservoir tank. If the clutch fluid level is below “MIN”, fill the clutch fluid up to “MAX” level, and make sure that there is no leakage.

6) Bleed air from the clutch fluid. 7) Install the air intake boot assembly. (non-turbo model) 8) Install the intercooler. (turbo model) 9) Install the collector cover.

(C)

(A) (B)

CL-00753

(A) MAX. level (B) MIN. level (C) Reservoir tank

B: REPLACEMENT CAUTION: • Use new FMVSS No. 116 DOT3. • Cover the air bleeder with cloth to prevent clutch fluid from being splashed on surrounding parts when loosening the bleeder. • Avoid mixing clutch fluid of different brands to prevent fluid performance from degrading. • Be careful not to allow dirt or dust to enter the reservoir tank. NOTE: • During bleeding operation, keep the clutch reservoir tank filled with clutch fluid to prevent entry of air. • Clutch pedal must be operated very slowly. • Bleed air from the oil line with help of a co-worker. • The amount of clutch fluid required is approximately 70 m2 (2.4 US fl oz, 2.5 Imp fl oz) for total clutch system. 1) Remove the collector cover. 2) Remove the air intake boot assembly. (non-turbo model) 3) Remove the intercooler. (turbo model) 4) Drain clutch fluid from reservoir tank completely. 5) Refill the reservoir tank with recommended clutch fluid.

Recommended clutch fluid: New FMVSS No. 116 DOT3

CL-24

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Clutch Fluid Air Bleeding CLUTCH SYSTEM

9. Clutch Fluid Air Bleeding

7) Tighten the air bleeder.

A: PROCEDURE

Tightening torque: T: 7.8 N·m (0.8 kgf-m, 5.8 ft-lb)

NOTE: • The illustration shows a representing model. Perform the same procedures for the other models. • Bleed air from the oil line with help of a co-worker. 1) Remove the collector cover. 2) Remove the air intake boot assembly. (non-turbo model) 3) Remove the intercooler. (turbo model) 4) Fit one end of a vinyl tube into the air bleeder of the operating cylinder, and put the other end into a clutch fluid container.

T CL-00712

8) After stepping on the clutch pedal, make sure that there are no leaks evident in the entire clutch system. 9) After bleeding the air from clutch system, ensure that the clutch operates properly. 10) Install the air intake boot assembly. (non-turbo model) 11) Install the intercooler. (turbo model) 12) Install the collector cover.

(A) CL-00777

(A) Air bleeder

5) Slowly depress the clutch pedal several times and keep it depressed. Then open the air bleeder to discharge air together with the clutch fluid. Release the air bleeder for 1 or 2 seconds. Next, close the air bleeder, and slowly release the clutch pedal. CAUTION: Cover the air bleeder with cloth to prevent clutch fluid from being splashed on surrounding parts when loosening the bleeder.

(A) (B) CL-00711

(A) Operating cylinder (B) Vinyl tube

6) Repeat step 3) until there are no more air bubbles from the air bleeder.

CL-25

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Clutch Pedal CLUTCH SYSTEM

10.Clutch Pedal

NOTE: Place vinyl, etc. not to drop the clutch fluid to the floor carpet.

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the collector cover. 3) Drain the clutch fluid from the reservoir tank. 4) Disconnect the clutch pipe from the connector.

(B) (A)

CL-00752

(A) Connector (B) Clutch pipe

5) Disconnect the reservoir tank hose from the reservoir tank. CL-00756

B: INSTALLATION

(A)

1) Install in the reverse order of removal. CAUTION: Always use a new clevis pin. (B)

(C)

CL-00751

(A) Reservoir tank (B) Reservoir tank hose (C) Clamp

6) Remove the instrument panel lower cover. 7) Remove the body integrated unit. 8) Disconnect the connector from clutch switch. 9) Disconnect the connector from the brake switch. 10) Remove the snap pin and clevis pin connecting the operating rod and brake pedal. 11) Remove the pedal assembly.

Tightening torque: T: 18 N·m (1.8 kgf-m, 13.3 ft-lb) 2) Fill the recommended clutch fluid. 3) Bleed air from the clutch system. 4) Adjust the clutch pedal. 5) When the clutch pedal has been replaced, perform the clutch sensor calibration mode. NOTE: If necessary, perform the clutch meet position setting. 6) Install the collector cover.

CL-26

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Clutch Pedal CLUTCH SYSTEM

C: DISASSEMBLY 1) Disconnect the clutch pipe from the master cylinder.

NOTE: Secure the push rod with a tape, etc. to prevent it from falling off.

(A)

CL-00769

CL-00754

2) Remove the clutch damper mounting nut from the pedal assembly, and disconnect the clutch pipe from the clamp.

(A) Master cylinder

7) Remove the torsion spring and assist bushing from the pedal assembly.

(B) (B) (A) CL-00767 CL-00772

3) Remove the clutch switches. 4) Remove the clip and pull out the clevis pin.

(A) Torsion spring (B) Assist bushing

8) Remove the clutch pedal from the pedal bracket. NOTE: Before removing the clutch pedal mounting bolt, remove the hook of the assist spring from the pedal bracket. (turbo model)

(B)

(A)

(A)

CL-00768

(A) Clevis pin (B) Clip

5) Disconnect the connector from the clutch stroke sensor, and then remove the sensor harness. 6) Remove the master cylinder from the pedal assembly.

(B)

CL-00770

(A) Clutch pedal (B) Assist spring (turbo model)

CL-27

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Clutch Pedal CLUTCH SYSTEM

9) Remove the assist spring (turbo model), bushing, spacer, bushing A, stopper, torsion spring bushing and clutch pedal pad from the clutch pedal.

Tightening torque: T: 30 N·m (3.1 kgf-m, 22.1 ft-lb) (A)

(C) (B)

(B) (A)

(D) (F)

T

(G)

(B)

(E) (E) (H)

CL-00774 CL-00773

(A) (B) (C) (D) (E) (F) (G) (H)

(A) Clutch pedal (B) Assist spring (turbo model)

Assist spring (turbo model) Bushing SPACER Bushing A STOPPER Torsion spring bushing Clutch pedal pad Clutch pedal

4) Install the assist bushing and torsion spring to the pedal assembly. NOTE: Before installing the torsion spring, apply grease to the assist bushing and torsion spring bushing. 5) Install the master cylinder to the pedal assembly.

D: ASSEMBLY 1) Clean the holes in the sliding surface between the clutch pedal and pedal bushing, and apply grease. 2) Attach the pedal pad, stopper, assist spring (turbo model), bushing A, torsion spring bushing, spacer and bushing to the clutch pedal.

NOTE: Secure the push rod with a tape, etc. to prevent it from falling off.

Tightening torque: T: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

NOTE: Before installing the spacer, clean the inside of the pedal bushings and apply grease. 3) Attach the clutch pedal to the pedal bracket.

(A)

NOTE: • Before installing the assist spring, apply grease to the coil part of the assist spring. (turbo model) • Hang hook of the assist spring on the pedal bracket. (turbo model)

CL-00769

(A) Master cylinder

6) Secure the clevis pin with mounting clip. CAUTION: Always use a new clevis pin.

CL-28

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Clutch Pedal CLUTCH SYSTEM

E: INSPECTION

NOTE: Before installing the clevis pin, apply grease.

1. CLUTCH PEDAL Move the clutch pedal in the lateral direction with a force of approximately 10 N (1 kgf, 2 lbf) to check that the clutch pedal deflection is within the service limit.

(B)

CAUTION: If the deflection exceeds the service limit, replace with a new clutch pedal assembly.

(A)

Deflection of the clutch pedal: Service limit 4.0 mm (0.157 in) or less

CL-00768

(A) Clevis pin (B) Clip

7) Attach the sensor harness, and connect the connector to the clutch stroke sensor. 8) Install the clutch switch. 9) Install the clutch damper to the pedal assembly, and connect the clutch pipe to the master cylinder.

(B)

(A)

Tightening torque: T1: 15 N·m (1.5 kgf-m, 11.1 ft-lb) T2: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

CL-00758

(A) Clutch pedal (B) Brake pedal

T1

F: ADJUSTMENT 1) If the full stroke of the clutch pedal is not within the specified value, loosen the lock nuts of the clutch switch and adjust the full stroke of the clutch pedal with the clutch switch.

T2

T1

CL-00771

CAUTION: When adjusting the full stroke of clutch pedal, do not turn the clutch switch.

Clutch pedal full stroke A: 130 — 135 mm (5.12 — 5.31 in) (non-turbo model) 135 — 140 mm (5.31 — 5.51 in) (turbo model) Tightening torque: T: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

T

A CL-00775

CL-29

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Clutch Pedal CLUTCH SYSTEM

2) Depress and release the clutch pedal two or three times to ensure that the clutch pedal and release lever operate smoothly. If the clutch pedal and release lever do not operate smoothly, bleed air from the clutch hydraulic system. 3) Measure the clutch pedal full stroke length again to ensure that it is within specifications. If it is not within specifications, repeat adjustment procedures again from the beginning.

6) If the clutch fluid level increases, hydraulic clutch play is correct. 7) If the clutch fluid level does not increase or push rod does not retract, readjust the clutch pedal. 8) Check the clutch fluid level using the scale on the outside of the reservoir tank. If the clutch fluid level is below “MIN”, fill the clutch fluid up to “MAX” level.

Recommended clutch fluid: New FMVSS No. 116 DOT3

Clutch pedal full stroke: 130 — 135 mm (5.12 — 5.31 in) (non-turbo model) 135 — 140 mm (5.31 — 5.51 in) (turbo model) 4) Push the release lever until the operating cylinder push rod retracts. Make sure that the clutch fluid level in the reservoir tank increases. If the clutch fluid level increases, the hydraulic clutch is properly adjusted; If the clutch fluid level does not increase or the push rod does not retract, replace the master cylinder with a new part. (A)

(B) (C)

CL-00713

(A) Push rod (B) Release lever (C) Operating cylinder

5) Push the release lever until the operating cylinder push rod retracts. Check that the clutch fluid level in the reservoir tank increases. (A)

(B) (C)

CL-00713

(A) Push rod (B) Release lever (C) Operating cylinder

CL-30

(C)

(A) (B)

CL-00753

(A) MAX. level (B) MIN. level (C) Reservoir tank

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Clutch Switch CLUTCH SYSTEM

11.Clutch Switch

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. 3) Disconnect the connector from clutch switch. 4) Remove the clutch switches.

(B) (D)

(A)

(C)

B: INSTALLATION 1. CLUTCH SWITCH

CL-00776

1) Move the clevis pin of push rod to left and right, retain it at the position where it moves smoothly, and measure the clutch pedal stroke.

Clutch pedal full stroke A: 130 — 135 mm (5.12 — 5.31 in) (non-turbo model) 135 — 140 mm (5.31 — 5.51 in) (turbo model) Tightening torque: T: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

(A) (B) (C) (D)

2.9 mm (0.11 in) Clutch pedal plate Clutch start switch Lock nut

3) Connect the connector to the clutch start switch. 4) Make sure that engine does not start with clutch pedal not depressed. 5) Make sure that engine starts with clutch pedal fully depressed.

C: INSPECTION 1) If the clutch start switch does not operate properly (or it does not stop at the specified position), replace it with a new part. T

Specified position L: 4+1.5/0 mm (0.157+0.059 /0 in)

A CL-00775 L

2) If the clutch pedal stroke is out of specification, adjust the stroke. 3) Connect the connector to the clutch switch.

2. CLUTCH START SWITCH 1) Fully depress the clutch pedal and hold it. 2) Install so that gap (A) of the clutch pedal plate and clutch start switch is 2.9 mm (0.11 in), and tighten the lock nut.

CL-00231

2) Check the clutch switch for continuity. If the continuity is not at the standard value, replace the switch. (1) Disconnect the connector from clutch switch. (2) Measure the resistance between terminal 1 and 2 of the switch.

CL-31

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Clutch Switch CLUTCH SYSTEM

D: ADJUSTMENT

• Clutch switch Terminal No.

Specified resistance

When clutch pedal is depressed

No. 1 — No. 2

1 MΩ or more

Except when clutch pedal is depressed

No. 1 — No. 2

Less than 1 Ω

Condition

1) Loosen the lock nut of the clutch start switch. 2) Fully depress the clutch pedal and hold it. 3) Adjust the gap (A) of the clutch pedal plate and the clutch start switch to be 2.9 mm (0.11 in).

(B) (D)

2 1

(A)

(C)

CL-00776

(A) (B) (C) (D)

CL-00084

• Clutch start switch Terminal No.

Specified resistance

When clutch pedal is depressed

No. 1 — No. 2

Less than 1 Ω

Except when clutch pedal is depressed

No. 1 — No. 2

1 MΩ or more

Condition

2.9 mm (0.11 in) Clutch pedal plate Clutch start switch Lock nut

4) Tighten the lock nut.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

1 2

CL-00102

(3) Connect the connector to the clutch switch. 3) Make sure that engine does not start with clutch pedal not depressed. If the engine starts, adjust the clutch switch and inspect the clutch start circuit. 4) Make sure that engine starts with clutch pedal fully depressed. If the engine does not start, adjust the clutch switch and inspect the clutch start circuit.

CL-32

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General Diagnostic Table CLUTCH SYSTEM

12.General Diagnostic Table A: INSPECTION 1. CLUTCH Symptoms 1. Clutch slippage. It is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms. • Engine speeds up when shifting. • High-speed driving is not possible; especially rapid acceleration is not possible and vehicle speed does not increase in proportion to the increase in engine speed. • Power drops particularly when ascending a slope, and there is a burning smell of the clutch plate. • Method of testing: Park the vehicle and fully apply the parking brake. Disengage the clutch and shift the transmission gear into the 1st. Gradually increase the engine speed while gradually allowing the clutch to engage. The clutch function is satisfactory if the engine stalls. However, the clutch is slipping if the vehicle does not move forward and the engine does not stall. 2. Clutch drags. As a symptom of this trouble, a harsh scratching noise occurs and control becomes difficult when shifting gears. The symptom becomes more apparent when shifting into the 1st gear. However, because most trouble of this sort is due to a defective synchronization mechanism, perform the following tests. • Method of testing: The problem is caused by insufficient disengagement of the clutch if an abnormal noise occurs during this test.

Possible cause

Corrective action

(a) Oil on the clutch face (b) Worn clutch face (c) Deteriorated diaphragm spring (d) Warped pressure plate or flywheel (e) Defective release bearing holder

Replace. Replace. Replace. Repair or replace. Repair or replace.

(a) Worn or rusty clutch disc hub spline (b) Excessive deflection of clutch disc face (c) Crankshaft pilot needle bearing sticking (d) Cracked clutch disc face (e) Stuck clutch disc (smeared by oil or water)

Replace the clutch disc. Repair or replace.

3. Clutch chatters. Clutch chattering is an unpleasant vibration to the whole vehicle when the vehicle is just started with clutch partially engaged.

(a) Adhesion of oil on the clutch face (b) Weak or broken damper spring (c) Poor contact of the disc surface or excessively worn disc (d) Warped pressure plate or flywheel (e) Loose disc rivets (f) Loose engine mounting

Replace the clutch disc. Replace the clutch disc. Replace the faulty clutch disc.

4. Noisy clutch Examine whether the noise is generated when the clutch is disengaged, engaged, or partially engaged.

(a) Broken, worn or insufficiently lubricated release bearing (b) Insufficient lubrication of the pilot bearing (c) Loose clutch disc hub (d) Loose damper spring retainer (e) Deteriorated or broken damper spring

Replace the release bearing.

CL-33

Replace. Replace. Replace.

Repair or replace. Replace the clutch disc. Retighten or replace mounting.

Replace the pilot bearing. Replace the clutch disc. Replace the clutch disc. Replace the clutch disc.

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General Diagnostic Table CLUTCH SYSTEM Symptoms 5. Clutch grabs suddenly. When starting the vehicle with the clutch partially engaged, the clutch engages suddenly and the vehicle jumps instead of making a smooth start.

Possible cause (a) Grease or oil on facing (b) Deteriorated cushioning spring (c) Worn or rusted spline of clutch disc or main shaft (d) Deteriorated or broken damper spring (e) Loose engine mounting (f) Deteriorated diaphragm spring

Corrective action Replace the clutch disc. Replace the clutch disc. Take off rust, apply grease or replace clutch disc or main shaft. Replace the clutch disc. Retighten or replace mounting. Replace.

2. CLUTCH PEDAL Symptoms Insufficient clutch pedal play Excessive wear and damage of pedal shaft or busing

Corrective action Adjust the pedal play. Replace the busing or shaft with a new part.

3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG 1

2

3

Step CHECK GEAR NOISE. 1) Start the engine. 2) While idling the engine, step on the clutch pedal and quickly shift from neutral to reverse. CHECK GEAR NOISE. Step on the clutch pedal at idle and shift from neutral to reverse within 0.5 — 1.0 second.

Check Is there any abnormal noise from the transmission gear?

Yes Go to step 2.

No Clutch is normal.

Is there any abnormal noise from the transmission gear?

Go to step 3.

Defective transmission or excessive clutch drag torque. Inspect pilot bearing, clutch disc, transmission and clutch disc hub spline. Clutch and flywheel seizure. Inspect the clutch disc and the spline of the clutch disc hub.

CHECK GEAR NOISE. Is there any abnormal noise 1) Step on the clutch pedal at idle and shift from the transmission gear? from neutral to reverse within 0.5 — 1.0 second. 2) While stepping on the clutch pedal, shift from neutral to reverse, reverse to neutral several times.

CL-34

Inadequate clutch disengage. Inspect the clutch disc, clutch cover, clutch release, and clutch pedal free play.

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2010 LEGACY SERVICE MANUAL

QUICK REFERENCE INDEX

CHASSIS SECTION

This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of 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.

FRONT SUSPENSION

FS

REAR SUSPENSION

RS

WHEEL AND TIRE SYSTEM

WT

TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

TPM(diag)

DIFFERENTIALS

DI

TRANSFER CASE

TC

DRIVE SHAFT SYSTEM

DS

VEHICLE DYNAMICS CONTROL (VDC)

VDC

VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS)

VDC(diag)

BRAKE

BR

PARKING BRAKE

PB

PARKING BRAKE (DIAGNOSTICS)

PB(diag)

POWER ASSISTED SYSTEM (POWER STEERING)

PS

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD.

G2460BE6

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FRONT SUSPENSION

FS 1. 2. 3. 4. 5. 6. 7. 8.

Page General Description ...................................................................................2 Wheel Alignment ........................................................................................8 Cradle .......................................................................................................15 Front Stabilizer .........................................................................................19 Front Ball Joint .........................................................................................20 Front Arm .................................................................................................22 Front Strut ................................................................................................25 General Diagnostic Table .........................................................................28

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General Description FRONT SUSPENSION

1. General Description A: SPECIFICATION Tire size Wheel arch height (Tolerance: +12 mm –24 mm (+0.47 in –0.94 in ))

mm (in) Camber (Tolerance: ±0°45′ Differences between RH and LH: 45′ or less) Caster (Referential Value)

Front

Inner wheel Outer wheel mm (in)

Steering angle (Tolerance: ±1.5°)

REAR

Toe-in Kingpin angle (Referential Value) Wheel arch height (Tolerance: +12 mm –24 mm (+0.47 in –0.94 in )) mm (in) Camber (Tolerance: ±0°45′ Differences between RH and LH: 45′ or less) Toe-in mm (in) Thrust angle (Tolerance: ±0°30′)

*1

P205/60R16 P215/50R17

P225/50R17 225/45R18

P225/60R17 P215/70R16

403 (15.9)

395 (15.6)

469 (18.5)

–0°30′

–0°15′

0°00′

5°55′

6°00′

5°05′

37.6° 37.4° 38.4° 33.3° 33.0° 34.1° 0±3 (0±0.12) Toe angle (sum of both wheels): 0°±0°15′ 14°00′ 14°15′ 12°20′ 392 (15.4)

387 (15.2)

474 (18.7)

–1°00′

–1°10′

0°00′

: OUTBACK model 2±3 mm (0.08 — 0.12 in) Toe angle (sum of both wheels): 0°10′±0°15′ *2: Except for OUTBACK model 0±3 mm (0±0.12 in) Toe angle (sum of both wheels): 0°±0°15′

NOTE: • Front and rear toe-in and front camber can be adjusted. Adjust if the toe-in or camber tolerance exceeds specifications. • For other items indicated in the specifications table, there is no adjustment mechanism. If other items exceed specifications, check the suspension parts and connections for deformation, and replace the parts if defective.

B

(1)

A FS-00269

(1) Front A – B = Positive: Toe-in, Negative: Toe-out α = Individual toe angles

FS-2

*2

*1



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General Description FRONT SUSPENSION

B: COMPONENT T4 (26)

T8 T7

(5)

(27)

T9

T8 (3)

(12)

T4

(1)

T5

T4

(2)

T9

(4)

T2 T9

T9

T9 T10

T1

(15) (6)

T6 (12) (16) (17) (8)

(18) (14)

(12)

(9)

(7)

T11 (19) (20)

(24)

(10)

(25)

T3 (11)

(21)

T7

(29)

(28)

(28)

T7

(22) (30) (23) (13)

(12)

T12 FS-00383

FS-3

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General Description FRONT SUSPENSION (1)

Cradle

(16)

Strut mount

(2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Stiffener Main mounting bracket Front mounting bracket Front housing Rear bushing Front bushing Ball joint Front arm Castle nut Cotter pin Self-locking nut Stabilizer link Rubber seat (OUTBACK model only) Dust seal

(17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29)

SPACER Upper spring seat Dust cover Helper Coil spring STRUT Adjusting bolt Stabilizer bracket Stabilizer bushing STOPPER Stud bolt Flange nut Stabilizer (H4 model)

(30)

Stabilizer (H6 model)

(15)

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Use SUBARU genuine grease etc. or equivalent. Do not mix grease etc. of different grades or manufacturers. • Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points.

FS-4

Tightening torque:N·m (kgf-m, ft-lb) T1: 20 (2.0, 14.8) T2: 25 (2.5, 18.4) T3: 39 (4.0, 28.8) T4: 45 (4.6, 33.2) T5: 50 (5.1, 36.9) T6: 55 (5.6, 40.6) T7: 60 (6.1, 44.3) T8: 65 (6.6, 47.9) T9: 75 (7.6, 55.3) T10: 95 (9.7, 70.1) T11: 140 (14.3, 103.3) T12: 155 (15.8, 114.3)

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General Description FRONT SUSPENSION

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 927680000

DESCRIPTION INSTALLER & REMOVER SET

REMARKS Used for replacing front arm front bushing.

ST-927680000

99099AJ000 ENGINE HANGER (Newly adopted tool)

• Used for hanging power unit. • Used together with CHAIN BALANCER (99099AJ010).

99099AJ010 CHAIN BALANCER (Newly adopted tool)

• Used for hanging power unit. • Used together with ENGINE HANGER (99099AJ000).

ST99099AJ000

ST99099AJ010

10004AA180 (SUBARU genuine part)

HANGER CP ENGINE RR

ST10004AA180

FS-5

• Used for hanging power unit. • For H4 - non-turbo model. • SUBARU genuine part

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General Description FRONT SUSPENSION ILLUSTRATION

TOOL NUMBER DESCRIPTION 18360AA020 HANGER (Newly adopted tool)

REMARKS • Used for hanging power unit. • For H6 model.

41099AJ000 SPECIAL TOOL H4 (Newly adopted tool)

Used for removing and installing front stabilizer. (for turbo model)

ST18360AA020

ST41099AJ000

20299AG000

REMOVER

• Used for replacing front arm rear bushing. • Used together with BASE (20999AG010).

20299AG010

BASE

• Used for replacing front arm rear bushing. • Used together with REMOVER (20299AG000).

20299AG020

STUD BOLT SOCKET

Used for removing and installing the stud bolt for front arm installing portion.

ST20299AG000

ST20299AG010

ST20299AG020

FS-6

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General Description FRONT SUSPENSION ILLUSTRATION

TOOL NUMBER 20399AG000

DESCRIPTION STRUT MOUNT SOCKET

REMARKS Used for disassembling and assembling strut mount.

ST20399AG000

2. GENERAL TOOL TOOL NAME Alignment gauge Alignment gauge adapter Turning radius gauge Toe-in gauge Dial gauge Coil spring compressor Chain sling

Shackle

Sling belt

Shackle

REMARKS Used for measuring wheel alignment. Used for measuring wheel alignment. Used for measuring wheel alignment. Used for toe-in measurement. Used for damper strut measurement. Used for strut assembly/disassembly. • Used for hanging power unit. • Diameter: 6 mm (0.24 in) or 6.3 mm (0.25 in) • Length: 0.8 — 1 m (2.6 — 3.3 ft) • Chain inner width: 8.5 mm (0.33 in) or more • Chain external width: 23.5 mm (0.93 in) or less • Load capacity: 1.2 t (2646 lb) or more • Two units used for hanging power unit. • Attached to both end of chain sling and connected to engine hook. • Load capacity: 250 kg (551 lb) or more • Used to remove and install the cradle. • Width: 35 — 40 mm (1.38 — 1.57 in) • Length: 2 m (6.6 ft) • Load capacity: 1 t (2205 lb) or more • Used to remove and install the cradle. • Load capacity: 500 kg (1103 lb) or more

FS-7

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Wheel Alignment FRONT SUSPENSION

2. Wheel Alignment A: INSPECTION Check the following items before performing the wheel alignment measurement. • Tire inflation pressure • Uneven wear of RH and LH tires, or difference of sizes • Tire runout • Excessive play and wear of ball joint • Excessive play and wear of tie-rod end • Excessive play of wheel bearing • Right and left wheel base imbalance • Deformation and excessive play of steering link • Deformation and excessive play of suspension parts Check, adjust and measure the wheel alignment in accordance with the procedures indicated in the figure. Wheel arch height (front and rear wheels)

↓ Camber (front and rear wheels)

↓ Caster (front wheel)

↓ Steering angle

↓ Front wheel toe-in

↓ Rear wheel toe-in

↓ Thrust angle

FS-8

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2015年12月24日 木曜日 午後5時18分

Wheel Alignment FRONT SUSPENSION

1. WHEEL ARCH HEIGHT 1) Park the vehicle on a level surface. 2) Empty the vehicle so that it is at “curb weight”. (Empty the luggage compartment, load the spare tire, jack and service tools, and fill up the fuel tank.) 3) Set the steering wheel in a straight-ahead position, and stabilize the suspension by moving the vehicle in a straight line for 5 m (16 ft) or more. 4) Suspend a thread from the wheel arch (point “A” in the figure below) and affix at a position directly above the center of wheel. 5) Measure the distance between the point “A” and the center of wheel.

(2)

(3)

A (1) (1) A

A

(6)

(7)

(4)

(1)

(5)

(8) FS-00345

(1) (2) (3)

Wheel arch height Front fender Rear quarter

(4) (5) (6)

Front wheel arch height Rear wheel arch height Flange bend line

(7) (8)

Point of measurement End of spindle

Wheel arch height specification mm (in) (Tolerance: +12 mm –24 mm (+0.47 in –0.94 in )) Tire size Front REAR

P205/60R16 P215/50R17 403 (15.9) 392 (15.4)

P225/50R17 225/45R18 395 (15.6) 387 (15.2)

FS-9

P225/60R17 P215/70R16 469 (18.5) 474 (18.7)

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2015年12月24日 木曜日 午後5時18分

Wheel Alignment FRONT SUSPENSION

2. CAMBER • INSPECTION 1) Place the front wheel on the turning radius gauge. Make sure the ground contact surfaces of the front and rear wheels are at the same height. 2) Set the adapter into the center of wheel, and then set the wheel alignment gauge.

NOTE: Moving the adjusting bolt by one scale changes the camber by approximately 0°15′. (1)

(4)

(3)

(6)

(5)

(7)

(1)

(2) FS-00213

(1) Alignment gauge (2) Turning radius gauge (3) Adapter

(2)

3) Measure the camber angle in accordance with the operation manual for wheel alignment gauge. Model

Camber (Difference between RH and LH 45′ or less)

P205/60R16 P215/50R17

–0°30′±0°45′

P225/50R17 225/45R18

–0°15′±0°45′

P225/60R17 P215/70R16

0°00′±0°45′

1) When adjusting the camber, adjust it to the following value.

P205/60R16 P215/50R17 P225/50R17 225/45R18 P225/60R17 P215/70R16

FS-00008

(1) (2) (3) (4) (5) (6) (7)

• FRONT CAMBER ADJUSTMENT

Model

(3)

Camber (Difference between RH and LH 45′ or less) –0°30′±0°30′ –0°15′±0°30′ 0°00′±0°30′

2) Loosen the two self-locking nuts located at the front lower section of the strut. NOTE: When the adjusting bolt needs to be loosened or tightened, hold its head with a wrench and turn the self-locking nut. 3) Turn the camber adjusting bolt so that the camber is set at specification.

FS-10

STRUT Adjusting bolt Housing Outer Inner Camber is increased. Camber is decreased.

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2015年12月24日 木曜日 午後5時18分

Wheel Alignment FRONT SUSPENSION To increase camber. Rotate the left side counterclockwise.

Rotate the right side clockwise.

FS-00352

FS-00353

To decrease camber. Rotate the left side clockwise.

Rotate the right side counterclockwise.

FS-00353

FS-00352

3) Measure the caster angle in accordance with the operation manual for wheel alignment gauge.

4) Tighten two new self-locking nuts.

Tightening torque: 155 N·m (15.8 kgf-m, 114.3 ft-lb)

Model P205/60R16 P215/50R17

3. CASTER • INSPECTION 1) Place the front wheel on the turning radius gauge. Make sure the ground contact surfaces of the front and rear wheels are at the same height. 2) Set the adapter into the center of wheel, and then set the wheel alignment gauge.

Caster 5°55′

P225/50R17 225/45R18

6°00′

P225/60R17 P215/70R16

5°05′

4. STEERING ANGLE • INSPECTION

(3)

1) Place the vehicle on turning radius gauge. 2) While depressing the brake pedal, turn the steering wheel fully to the left and right. With the steering wheel held at each fully turned position, measure both the inner and outer wheel steering angles.

(1)

Model P205/60R16 P215/50R17

(2) FS-00213

(1) Alignment gauge (2) Turning radius gauge (3) Adapter

P225/50R17 225/45R18 P225/60R17 P215/70R16

FS-11

Inner wheel

Outer wheel

37.6°±1.5°

33.3°±1.5°

37.4°±1.5°

33.0°±1.5°

38.4°±1.5°

34.1°±1.5°

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2015年12月24日 木曜日 午後5時18分

Wheel Alignment FRONT SUSPENSION

• ADJUSTMENT 1) Turn the tie-rod to adjust the steering angle of both inner and outer wheels. 2) Check the toe-in. NOTE: Correct the boot if it is twisted.

2) Loosen the left and right side steering tie-rod lock nuts. 3) Turn the left and right tie-rods by equal amounts until the toe-in is at the specification. Both the left and right tie-rods are right-hand threaded. To increase toe-in, turn both tie-rods clockwise by equal amount (viewing from the inside of vehicle).

(1) (1)

FS-00014 FS-00014

(1) Lock nut (1) Lock nut

5. FRONT WHEEL TOE-IN • INSPECTION

4) Tighten the tie-rod lock nut.

Toe-in: 0±3 mm (0±0.12 in) 1) Set the toe-in gauge in the position at wheel axis center height behind the right and left front tires. 2) Place a mark at the center of both left and right tires, and measure distance “A” between the marks. 3) Move the vehicle forward to rotate the tires 180°.

Tightening torque: 85 N·m (8.7 kgf-m, 62.7 ft-lb)

NOTE: Be sure to rotate the tires in the forward direction. 4) Measure the distance “B” between the left and right marks. Find toe-in using the following calculation:

A – B = Toe-in

B

NOTE: Check and correct the tie-rod boot if twisted.

6. REAR WHEEL TOE-IN • INSPECTION

Toe-in: Except for OUTBACK model 0±3 mm (0±0.12 in) OUTBACK model 2±3 mm (0.08±0.12 in) Refer to FRONT WHEEL TOE-IN for rear toe-in inspection procedures.

• ADJUSTMENT

A

When adjusting, adjust it to the following value.

Toe-in: Except for OUTBACK model 0±2 mm (0±0.08 in) OUTBACK model 2±2 mm (0.08±0.08 in) 1) Loosen the self-locking nut on the inner side of front lateral link.

FS-00015

• ADJUSTMENT When adjusting the toe-in, adjust it to the following value.

Toe-in: 0±2 mm (0±0.08 in) 1) Check that the left and right wheel steering angles are within specification.

FS-12

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2015年12月24日 木曜日 午後5時18分

Wheel Alignment FRONT SUSPENSION

NOTE: When loosening or tightening the adjusting bolt, hold the bolt head and turn the self-locking nut. (2)

(1)

FS-00372

(1) Adjusting bolt (2) Lateral link

2) Turn the adjusting bolt until toe-in is within the specification. NOTE: When the left and right wheels are adjusted for toein at the same time, the movement of one scale graduation changes toe-in by approx. 1.3 mm (0.05 in). To increase toe-in. Rotate the left side clockwise.

Rotate the right side counterclockwise.

FS-00018

FS-00019

To decrease toe-in. Rotate the left side counterclockwise.

Rotate the right side clockwise.

FS-00019

FS-00018

FS-13

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2015年12月24日 木曜日 午後5時18分

Wheel Alignment FRONT SUSPENSION

3) Attach and tighten a new self-locking nut.

2) When one rear wheel is adjusted in a toe-in direction, adjust the other rear wheel equally in toeout direction, in order to make the thrust angle adjustment. 3) When the left and right adjusting bolts are turned by one graduation, the thrust angle will change approx. 15′ (“L” is approx. 11 mm (0.43 in)).

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb)

7. THRUST ANGLE • INSPECTION 1) Park the vehicle on a level surface. 2) Move the vehicle 3 to 4 meters (10 to 13 feet) straight forward. 3) Draw the center of loci for both the front and rear axles. 4) Measure distance “L” between the center lines of the axle loci.

NOTE: Thrust angle is a mean value of left and right wheel toe angles in relation to the vehicle body center line. Vehicle is driven straight in the thrust angle direction while slanting in the oblique direction depending on the degree of the mean thrust angle. (1)

Thrust angle: 0°±30′ Less than 30′ when “L” is 23 mm (0.9 in) or less

(3)

(2)

(1)

FS-00024

(1) Front (2) Thrust angle (3) Body center line

(2)

Thrust angle: γ = (α – β)/2 α: Rear RH wheel toe-in angle β: Rear LH wheel toe-in angle Substitute only the positive toe-in values from each wheel into α and β in the calculation. (1)

(2)

L FS-00022

(1) Center line of loci (front axle) (2) Center line of loci (rear axle) FS-00976

• ADJUSTMENT When adjusting, adjust it to the following value.

Thrust angle: 0°±20′ Less than 20′ when “L” is 15 mm (0.6 in) or less 1) Make thrust angle adjustments by turning the toe-in adjusting bolts of the rear suspension equally in the same direction.

FS-14

(1) Front (2) Body center line

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2015年12月24日 木曜日 午後5時18分

Cradle FRONT SUSPENSION

3. Cradle

(1) Remove the clip and disconnect the hose from the pipe. (2) Remove the power steering hose bracket.

A: REMOVAL 1) Set the vehicle on a lift. 2) Position the tilt position of the steering column to the lowest position, and lock the tilt lever. 3) Prevent the steering wheel from turning using the seat belt.

(2) (1)

FS-00369

(1) Power steering hose (2) Power steering hose bracket

(3) Remove the hose from the power steering pump.

FS-00347

FS-00367

4) Remove the front wheels. 5) Disconnect the ground cable from battery. 6) Remove the air intake duct. 7) Remove the air intake boot assembly. (non-turbo model) 8) Remove the intercooler and the intercooler stay. (turbo model) 9) Remove the clips and remove the grille bracket.

NOTE: Plug the holes to prevent foreign objects from entering the removed hose and pipe. 11) Remove the throttle body from the intake manifold. NOTE: Do not disconnect the inlet and outlet hoses of engine coolant. 12) Replace the engine hanger installed on the engine with the SUBARU genuine engine hanger (H4 - non-turbo model) or ST (H6 model).

Tightening torque: 16 N·m (1.6 kgf-m, 11.8 ft-lb)

CO-02618

10) Remove the power steering hose bracket and power steering hose.

FS-15

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2015年12月24日 木曜日 午後5時18分

Cradle FRONT SUSPENSION

• H4 non-turbo model SUBARU genuine part 10004AA180 HANGER CP ENGINE RR

CAUTION: • Set the chain sling so that it does not contact the engine parts. ST2

ST1

FS-00348

FS-00343

• H6 model ST 18360AA020 HANGER

• Use a chain sling with the diameter of 6 mm (0.24 in) or 6.3 mm (0.25 in), the length of 0.8 — 1 m (2.6 — 3.3 ft), the chain inner width of 8.5 mm (0.33 in) or more, the chain outer width of 23.5 mm (0.93 in) or less and the load capacity of 1.2 t (2646 lb) or more.

ST

(2) (1) (3)

AT-05498

13) Hang the engine using ST, chain sling and shackle. (1) Set the ST on the vehicle. ST1 99099AJ000 ENGINE HANGER ST2 99099AJ010 CHAIN BALANCER

FS-00349

(1) Wire diameter (2) Inner width (3) Outer width

CAUTION: Set the arms of ST (ENGINE HANGER) at the locations shown in the figure. ST2

• Use a shackle with the load capacity of 250 kg (551 lb) or more. ST1

FS-00342

(2) Attach the shackle to the both ends of chain sling. (3) Pass the chain sling through the CHAIN BALANCER and secure the both ends to the hooks on the engine.

FS-16

FS-00325

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2015年12月24日 木曜日 午後5時18分

Cradle FRONT SUSPENSION

14) Remove the nuts connecting the main mount and the transmission mounting bracket.

19) Attach the sling belt so that it wraps around the both frames using the shackle.

RH

FS-00323

CAUTION: • Be sure to attach the sling belt to ensure safety in operation. • Use a sling belt with the length of 2 m (6.6 ft), the width of 35 — 40 mm (1.38 — 1.57 in) and the load capacity of 1 t (2205 lb) or more.

LH

AT-05499

15) Remove the universal joint. 16) Remove the front exhaust pipe. 17) Disconnect the front arm. FS-00324

• Use a shackle with the load capacity of 0.5 t (1103 lb) or more.

FS-00322

18) Disconnect the tie-rod end. FS-00325 (1)

20) Remove the bolt on the front cushion rubber.

(2)

(3)

DS-00474

(1) Cotter pin (2) Castle nut (3) Tie-rod end

FS-00326

FS-17

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2015年12月24日 木曜日 午後5時18分

Cradle FRONT SUSPENSION

21) Support the cradle with a transmission jack and remove the bolts and nuts.

CAUTION: Do not remove the stud bolt unnecessarily. Always replace the parts with new parts when removed.

(1)

(2) FS-00350 ST FS-00279

(1) Vehicle body (2) Stud bolt

B: INSTALLATION 1) Install in the reverse order of removal. NOTE: Replace the gasket of the throttle body with a new gasket. CAUTION: • Use a new bolt and self-locking nut. For parts which are not reusable, refer to “COMPONENT”.

• Perform installation of the universal joint when the tilt position of the steering column is at the lowest position. • Tighten the bolts of the universal joint in the order of gearbox side and column shaft side.

FS-00327

22) Remove the cradle from the vehicle. CAUTION: The cradle is heavy. Remove it carefully by paying attention to the balance.

Tightening torque:

2) Inspect the wheel alignment and adjust if necessary.

FS-00368

23) To remove the stud bolt, use the ST. ST 20299AG020 STUD BOLT SOCKET

FS-18

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2015年12月24日 木曜日 午後5時18分

Front Stabilizer FRONT SUSPENSION

4. Front Stabilizer A: REMOVAL 1) Lift up the vehicle, and then remove the front wheels. 2) Remove the front under cover. 3) Remove the exhaust center pipe. (turbo model)

4) Remove the stabilizer link.

NOTE: For turbo model, it is required to secure space for operation to hang the engine and remove the stabilizer. 8) Turn the front stabilizer by approximately 180° toward the front of the vehicle and pull out the front stabilizer from the right side of the vehicle. (2)

(1)

FS-00351

(1) Turn toward the front of the vehicle. (2) Front side of vehicle FS-00328

B: INSTALLATION

5) Remove the stabilizer bracket.

Install in the reverse order of removal. CAUTION: The stabilizer bracket has a set orientation. Install it with the arrow mark facing the upper side of the vehicle. (1)

FS-00329

6) Disconnect the tie-rod end.

(1)

FS-00330

(1) Front side of vehicle

(2)

(3)

Tightening torque: Stabilizer bracket: 25 N·m (2.5 kgf-m, 18.4 ft-lb) Stabilizer link: 60 N·m (6.1 kgf-m, 44.3 ft-lb)

DS-00474

(1) Cotter pin (2) Castle nut (3) Tie-rod end

7) Hang the engine and replace the front cushion mount with ST. (turbo model) ST 41099AJ000 SPECIAL TOOL H4

FS-19

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2015年12月24日 木曜日 午後5時18分

Front Ball Joint FRONT SUSPENSION

5. Front Ball Joint A: REMOVAL 1) Lift up the vehicle, and remove the front wheels. 2) Remove the both sides of stabilizer bracket. (3) (1) (2) (4) FS-00332

(1) (2) (3) (4)

FS-00329

3) Pull out the cotter pin from ball stud, remove the castle nut, and extract the ball stud from front arm. 4) Remove the bolt installing ball joint to housing.

Housing bottom Raised section of ball joint Housing Ball joint

2) Install the ball joint into front arm.

Tightening torque: 39 N·m (4.0 kgf-m, 28.8 ft-lb) 3) Retighten the castle nut further up to 60° until the hole in the ball stud is aligned with a slot in castle nut. Then, insert a new cotter pin and bend it around the castle nut. 4) Install the stabilizer bracket. NOTE: The stabilizer bracket has a set orientation. Install it with the arrow mark facing the upper side of the vehicle.

FS-00331

(1)

5) Extract the ball joint from housing.

B: INSTALLATION 1) Install the ball joint into housing.

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb) CAUTION: • Do not apply grease to the tapered portion of ball stud. • Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.

FS-00330

(1) Front side of vehicle

Tightening torque: 25 N·m (2.5 kgf-m, 18.4 ft-lb) 5) Install the front wheels.

FS-20

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2015年12月24日 木曜日 午後5時18分

Front Ball Joint FRONT SUSPENSION

C: INSPECTION 1) Measure the play of the ball joint using the following procedures. Replace with a new part if the play exceeds specification. (1) With 686 N (70 kgf, 154 lbf) loaded in direction shown in the figure, measure the length 21.

FS-00035

(2) With 686 N (70 kgf, 154 lbf) loaded in direction shown in the figure, measure the length 22.

FS-00036

(3) Determine free play using the following formula. S = 22 –21 (4) Replace with a new part if the play exceeds specification.

Front ball joint Specification for replacement S: Less than 0.3 mm (0.012 in) 2) If the play is within specification, visually check the dust cover. 3) If the dust cover is damaged, replace with a new ball joint.

FS-21

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2015年12月24日 木曜日 午後5時18分

Front Arm FRONT SUSPENSION

6. Front Arm

B: INSTALLATION

A: REMOVAL

1) Using new self-locking nuts, temporary tighten the front arm. 2) Install the ball joint into housing.

1) Lift up the vehicle, and then remove the front wheels. 2) Remove the front stabilizer link. 3) Remove the ball joint of front arm.

CAUTION: Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.

(3) (1) FS-00333

(2) (4)

4) Remove the bolts, then remove the front arm.

FS-00332

(1) (2) (3) (4)

Housing bottom Raised section of ball joint Housing Ball joint

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb) 3) Install the stabilizer link. Tightening torque: 60 N·m (6.1 kgf-m, 44.3 ft-lb) 4) Install the front wheels. 5) Unload the vehicle from lift, and tighten the bolt which secures the front arm to cradle with wheels in full contact with the ground and the vehicle at curb weight.

FS-00334

Tightening torque: Front bushing side 95 N·m (9.7 kgf-m, 70.1 ft-lb) Rear bushing side 140 N·m (14.3 kgf-m, 103.3 ft-lb) 6) Inspect the wheel alignment and adjust if necessary.

FS-22

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2015年12月24日 木曜日 午後5時18分

Front Arm FRONT SUSPENSION

C: DISASSEMBLY 1. FRONT BUSHING Using the ST and a press, remove the front bushing. ST 927680000 INSTALLER & REMOVER SET

2) Using the ST and a press, remove the rear bushing. ST1 20299AG000 REMOVER ST2 20299AG010 BASE (1) ST1 (2)

ST2

ST (3)

(1) PRESS (2) Front arm (3) Rear bushing

FS-00110

2. REAR BUSHING 1) Put an alignment mark on the front arm based on the center of rear bushing recess portion. CAUTION: Always put an alignment mark for aligning the position on bushing installation.

(1)

FS-00354

D: ASSEMBLY 1. FRONT BUSHING Assemble in the reverse order of disassembly.

2. REAR BUSHING 1) Align the center of recess portion with the alignment mark on the front arm, with the protrusion (A) of recess portion facing the front side of vehicle.

(2)

(1)

(1) (2)

FS-00335

(1) Put an alignment mark. (2) Recess section

(1)

(A) FS-00336

(1) Alignment mark (2) Recess section

FS-23

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2015年12月24日 木曜日 午後5時18分

Front Arm FRONT SUSPENSION

2) Using the ST and a press, install the rear bushing. ST1 20299AG000 REMOVER ST2 20299AG010 BASE (1) ST1 (2)

(3)

ST2 FS-00355

(1) PRESS (2) Front arm (3) Rear bushing

E: INSPECTION 1) Check the front arm for damage or cracks, and replace if defective. 2) Check the bushing for abnormal fatigue or damage.

FS-24

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2015年12月24日 木曜日 午後5時18分

Front Strut FRONT SUSPENSION

7. Front Strut

6) Remove the three nuts securing strut mount to body.

A: REMOVAL 1) Lift up the vehicle, and then remove the front wheels. 2) Place an alignment mark on the camber adjusting bolt and strut. 3) Remove the brake hose bracket.

FS-00337

4) Remove the ABS wheel speed sensor harness.

FS-00039

B: INSTALLATION 1) Install the strut mount at the upper side of strut to body, and tighten it with new self-locking nuts. FS-00338

5) Remove the two bolts securing the housing to the strut. NOTE: While holding the head of the adjusting bolt, loosen the self-locking nut.

Tightening torque: 20 N·m (2.0 kgf-m, 14.8 ft-lb) 2) Align alignment marks on the camber adjusting bolt and strut. Using new self-locking nuts, install the strut to the housing. NOTE: While holding the head of adjusting bolt, tighten the self-locking nut.

Tightening torque: 155 N·m (15.8 kgf-m, 114.3 ft-lb) 3) Secure the ABS wheel speed sensor harness bracket to the strut. 4) Install the brake hose bracket. Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb) 5) Install the front wheels. 6) Inspect the wheel alignment and adjust if necessary.

FS-25

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2015年12月24日 木曜日 午後5時18分

Front Strut FRONT SUSPENSION

C: DISASSEMBLY 1) Using a coil spring compressor, compress the coil spring.

2) Set the coil spring correctly so that its end face seats well in the spring seat as shown in the figure.

(1) FS-00043 FS-00040

(1) Coil spring end face

2) Using the ST, remove the self-locking nut. ST 20399AG000 STRUT MOUNT SOCKET

3) Install the dust cover and helper to the piston rod. 4) Pull the piston rod fully upward, and install the spring seat.

ST

NOTE: Position the upper spring seat as shown in the figure.

FS-00041

3) Remove the strut mount, spacer and upper spring seat from the strut. 4) Gradually decrease the compression force of compressor, and remove the coil spring. 5) Remove the dust cover and helper.

(1) FS-00128

D: ASSEMBLY 1) Using a coil spring compressor, compress the coil spring. NOTE: Make sure that the vertical install direction of the coil spring is as shown in the figure. (1)

(1) Outside of body

5) Install the spacer and strut mount to the piston rod, and temporarily tighten a new self-locking nut. 6) Using a hexagon wrench to prevent strut rod from turning, tighten the new self-locking nut with ST. ST 20399AG000 STRUT MOUNT SOCKET

Tightening torque: 55 N·m (5.6 kgf-m, 40.6 ft-lb)

(2)

ST

(3)

FS-00042

(1) Diameter is small (Upper part) (2) Identification paint (3) Diameter is large (Bottom part) FS-00041

7) Loosen the coil spring compressor carefully.

FS-26

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2015年12月24日 木曜日 午後5時18分

Front Strut FRONT SUSPENSION

E: INSPECTION

F: DISPOSAL

Check the removed part for wear, damage and cracks, and then repair or replace it if defective.

CAUTION: • Before handling struts, be sure to wear goggles to protect eyes from gas, oil and cutting powder. • Do not disassemble the strut damper or throw into flames. • When discarding gas filled struts, drill holes in them to purge the gas. 1) Place the strut on a level surface with the piston rod fully expanded. 2) Using a 2 — 3 mm (0.08 — 0.12 in) dia. drill, make holes in areas shown in the figure.

1. STRUT 1) Check for oil leaks. 2) Move the piston rod up and down to check that it operates smoothly without any hitch. 3) Piston rod play • Measure the play as follows: Fix the outer shell in place and fully extend the rod. Set a dial gauge at the end of rod L [10 mm (0.39 in)], and then read the dial gauge indication P1 while applying a force of W [20 N (2 kgf, 4 lbf)] to the threaded portion. Apply a force of 20 N (2 kgf, 4 lbf) from the opposite direction of “W”, and then read the dial gauge indication P2.

W (1) L

FS-00047

(1) 40 mm (1.57 in) FS-00046

Play limit (P1 + P2): 0.8 mm (0.031 in) If the play exceeds limit, replace the strut.

2. STRUT MOUNT Check the rubber part for deformation, abnormal cracks or deterioration, and then replace it with a new part if defective.

3. DUST COVER If abnormal cracks or damage are found, replace it with a new part.

4. COIL SPRING If a permanent strain is found, replaced it with a new part.

5. HELPER If abnormal cracks or damage are found, replace it with a new part.

FS-27

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General Diagnostic Table FRONT SUSPENSION

8. General Diagnostic Table A: INSPECTION 1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT Possible cause (1) Permanent distortion or damage of the coil spring (2) Rough operation of strut or shock absorber (3) Improper installation of strut or shock absorber (4) Installation of the wrong coil spring

Corrective action Replace. Replace. Replace with appropriate parts. Replace with appropriate parts.

2. POOR RIDE COMFORT 1) Large rebound shock 2) Rocking of the vehicle continues too long after running over bump and hump. 3) Excessive shock in bumping Possible cause

Corrective action

(1) Damaged coil spring (2) Overinflation of tires (3) Improper wheel arch height (4) Fault in operation of strut or shock absorber (5) Damage or deformation of strut mount or shock absorber mount (6) Unsuitable length (maximum or minimum) of strut or shock absorber (7) Abnormal deformation or loss of bushing (8) Deformation or damage of helper in strut assembly or shock absorber (9) Oil leakage from the strut or shock absorber

Replace. Adjust. Replace the coil springs with new parts. Replace. Replace. Replace with appropriate parts. Replace. Replace. Replace.

3. NOISE Possible cause (1) Wear or damage of strut or shock absorber component parts (2) Loosening of the suspension link installing bolt

Replace. Tighten to the specified torque.

(3) Deformation or loss of bushing (4) Unsuitable length (maximum or minimum) of strut or shock absorber (5) Damaged coil spring (6) Wear or damage of the ball joint (7) Deformation of the stabilizer clamp

Replace. Replace with appropriate parts. Replace. Replace. Replace.

FS-28

Corrective action

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REAR SUSPENSION

RS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Page General Description ...................................................................................2 Wheel Alignment ........................................................................................8 Rear Stabilizer ............................................................................................9 Rear Trailing Link .....................................................................................10 Upper Arm ................................................................................................13 Rear Shock Absorber ...............................................................................14 Front Lateral Link .....................................................................................15 Rear Lateral Link ......................................................................................16 Rear Sub Frame .......................................................................................17 General Diagnostic Table .........................................................................19

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General Description REAR SUSPENSION

1. General Description A: SPECIFICATION Refer to “FS” section for rear suspension specifications. NOTE: • Front and rear toe-in and front camber can be adjusted. Adjust if the toe-in or camber tolerance exceeds specifications. • For other items indicated in the specifications table, there is no adjustment mechanism. If other items exceed specifications, check the suspension parts and connections for deformation, and replace the parts if defective.

B

(1)

A FS-00269

(1) Front A – B = Positive: Toe-in, Negative: Toe-out α = Individual toe angles

RS-2

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General Description REAR SUSPENSION

B: COMPONENT 1. REAR SUSPENSION

(2) T1

(1) T7 T6 (2) (2)

(16)

(24) (22)

T6

C (9)

(3) T3 (19)

D

T7

(2) (2)

A B

C

(13)

A

(22)

T2 (21)

(21)

(17)

(24)

(4) T4

B

(12)

(2)

(14)

(18)

D T6

(5) (6) (2)

T8

(20)

(2)

(23)

(10)

T6 (15) T5

(7) (2)

T6

(15)

T2

(8)

T6 (25)

(11) T8 T7

(2)

RS-00326

RS-3

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General Description REAR SUSPENSION (1) (2) (3) (4) (5) (6) (7) (8) (9)

Shock absorber Self-locking nut Rear stabilizer Stabilizer bushing Stabilizer clamp Stabilizer link Rear lateral link Rear housing Upper arm

(14) (15) (16) (17) (18) (19) (20) (21) (22)

Snap pin Front sub frame support plate Rear sub frame Rear sub frame stopper lower Adjusting bolt Adjusting washer Rear lateral link bushing Flange nut Rear sub frame stopper upper (OUTBACK model)

(10) (11)

Trailing link Trailing link bushing

(23) (24)

(12) (13)

Front lateral link Front lateral link bushing

(25)

Trailing link rear bushing Rear sub frame stopper upper (except for OUTBACK model) Rear housing bushing

Tightening torque:N·m (kgf-m, ft-lb) T1: 30 (3.1, 22.1) T2: 33 (3.4, 24.3) T3: 38 (3.9, 28) T4: 60 (6.1, 44.3) T5: 70 (7.1, 51.6) T6: 80 (8.2, 59) T7: 120 (12.2, 88.5) T8: 200 (20.4, 147.5)

2. SHOCK ABSORBER

(4) (6)

T (1)

(2)

(3) (5)

(7)

RS-00286

(1) (2) (3) (4)

Mount Upper rubber sheet Dust cover Coil spring

(5) (6) (7)

Shock absorber Self-locking nut Helper

RS-4

Tightening torque:N·m (kgf-m, ft-lb) T: 25 (2.5, 18.4)

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General Description REAR SUSPENSION

C: CAUTION Please clearly understand and observe the following cautions. Please adhere to these cautions to avoid minor or serious injury to the person doing the work or people in the area.

1. EACH PROCEDURE • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Before disposing of shock absorbers, be sure to bleed the gas out completely. Also, do not expose to flames or fire. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Use SUBARU genuine grease etc. or equivalent. Do not mix grease etc. of different grades or manufacturers. • Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points.

2. OIL When handling oil, adhere to the following to prevent unexpected accident. • Prepare a container and cloth when performing work which oil possibly spills. If oil spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection. • Follow all government regulations concerning disposal of refuse when disposing.

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 20099AE000

DESCRIPTION INSTALLER & REMOVER

REMARKS Used for replacing the front lateral link bushing.

PRESS

Used for replacing the rear trailing link bushing.

ST20099AE000

499755602

ST-499755602

RS-5

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General Description REAR SUSPENSION ILLUSTRATION

TOOL NUMBER 20099AE010

DESCRIPTION INSTALLER & REMOVER

REMARKS Used for replacing the rear lateral link bushing.

BASE

Used for replacing the rear trailing link bushing.

INSTALLER

Used for replacing the rear trailing link bushing.

20399FG000

STRUT MOUNT SOCKET

• Used for removing and installing shock mount. • Used for checking torque of shock mount center nut.

28099PA090

OIL SEAL PROTEC- • Used for installing the rear drive shaft to the TOR rear differential. • For oil seal protection

ST20099AE010

20299AG010

ST20299AG010

899874100

ST-899874100

ST20399FG000

ST28099PA090

RS-6

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General Description REAR SUSPENSION ILLUSTRATION

TOOL NUMBER 20099PA010

DESCRIPTION INSTALLER & REMOVER

REMARKS • Used for replacing the bushing of the rear housing. • Used together with BUSHING REMOVER (20099FG000).

BUSHING REMOVER

• Used for replacing the bushing of the rear housing. • Used together with base part of INSTALLER & REMOVER (20099PA010).

ST20099PA010

20099FG000

ST20099FG000

2. GENERAL TOOL TOOL NAME Alignment tester Toe-in gauge Jack Bearing puller Coil spring compressor

REMARKS Used for measuring wheel alignment. Used for toe-in measurement. Used for removing and installing suspension. Used for removing bushings. Used for disassembling and assembling shock absorber.

RS-7

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Wheel Alignment REAR SUSPENSION

2. Wheel Alignment A: INSPECTION NOTE: Measure and adjust the front and rear wheel alignment at a time. Refer to FS section for measurement and adjustment of wheel alignment.

RS-8

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Rear Stabilizer REAR SUSPENSION

3. Rear Stabilizer A: REMOVAL 1) Lift up the vehicle, and then remove the rear wheels. 2) Remove the stabilizer link.

• When installing the stabilizer without paint mark, install it so that there is 6 mm (6.24 in) space between the Anti-Walk Ring (c) and the stabilizer bushing (b).

6 mm (6.24 in)

(b)

(c) RS-00365

Install in the reverse order of removal. RS-00251

Tightening torque: Stabilizer link 33 N·m (3.4 kgf-m, 24.3 ft-lb) Stabilizer clamp 38 N·m (3.9 kgf-m, 28 ft-lb)

3) Remove the stabilizer clamp.

C: INSPECTION 1) Check the bushing for abnormal cracks, fatigue or damages. 2) Check the stabilizer link for damage. RS-00313

B: INSTALLATION CAUTION: • Be sure to use a new flange nut and self-locking nut. • Always tighten the bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground. • When installing the stabilizer with paint mark (a), align the end of paint mark to the end of bushing (b).

(a)

(b) RS-00364

RS-9

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Rear Trailing Link REAR SUSPENSION

4. Rear Trailing Link

C: DISASSEMBLY

A: REMOVAL

1. REAR TRAILING LINK BUSHING

1) Lift up the vehicle, and then remove the rear wheels. 2) Remove the bracket, and remove the parking brake cable from the guide.

Using the ST A and ST B, press the bushing out. STA 8998741000 INSTALLER STB 499755602 PRESS

ST-A (1)

RS-00319

(1) GUIDE

3) Remove the trailing link.

ST-B

RS-00255

2. REAR HOUSING BUSHING 1) Remove the rear housing.

RS-00320

B: INSTALLATION CAUTION: • Be sure to use a new self-locking nut. • Always tighten the bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground. Install in the reverse order of removal.

Tightening torque: Rear trailing link to Rear sub frame 120 N·m (12.2 kgf-m, 88.5 ft-lb) Rear trailing link to Rear housing 80 N·m (8.2 kgf-m, 59 ft-lb)

RS-10

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Rear Trailing Link REAR SUSPENSION

2) Using the ST and a hydraulic press, push out the bushing. ST1 20099FG000 BUSHING REMOVER ST2 20099PA010 INSTALLER & REMOVER (BASE)

ST1

D: ASSEMBLY 1. REAR TRAILING LINK BUSHING Using the ST A and ST B, press-fit the bushing. STA 8998741000 INSTALLER STB 20299AG010 BASE CAUTION: Press-fit the bushing straight.

ST2 ST-A DS-00458

ST1

(1)

ST-B

RS-00256 (2)

ST2

DS-00459

2. REAR HOUSING BUSHING Press-fit the bushing using the ST and hydraulic press. ST1 20099FG000 BUSHING REMOVER ST2 20099PA010 INSTALLER & REMOVER (BASE)

(1) Rear housing (2) Bushing

RS-11

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Rear Trailing Link REAR SUSPENSION

CAUTION: Press-fit the bushing straight. ST1 (1)

(2) ST2 DS-00460

(1) Bushing (2) Rear housing

ST1

(1)

(2)

ST2

DS-00461

(1) Rear housing (2) Bushing

E: INSPECTION 1) Visually check the trailing link for damage and deformation. 2) Visually check the bushing for abnormal cracks, damages or fatigue.

RS-12

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Upper Arm REAR SUSPENSION

5. Upper Arm

B: INSTALLATION

A: REMOVAL

CAUTION: • Use a new self-locking nut. • Always tighten the bushing at the arm position; in the state where the vehicle is at curb weight and the wheels are in full contact with the ground. 1) Install in the reverse order of removal. 2) Inspect the wheel alignment and adjust if necessary.

1) Remove the rear ABS wheel speed sensor from the rear axle. CAUTION: • Be careful not to damage the sensor. • Do not apply excessive force to the sensor harness.

Tightening torque: Upper arm to Rear sub frame 80 N·m (8.2 kgf-m, 59 ft-lb) Upper arm to Rear housing 80 N·m (8.2 kgf-m, 59 ft-lb) Rear ABS wheel speed sensor bracket 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

C: INSPECTION

VDC00769

2) Remove the rear ABS wheel speed sensor bracket from the upper arm. NOTE: Leave the sensor harness clamp on the vehicle side.

1) Visually check the upper arm for damage and deformation. 2) Visually check the bushing for abnormal cracks, damages or fatigue.

VDC00770

3) Remove the rear sub frame. 4) Remove the bolts, then remove the upper arm.

RS-00258

RS-13

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Rear Shock Absorber REAR SUSPENSION

6. Rear Shock Absorber

D: ASSEMBLY

A: REMOVAL

Refer to “Front Strut” for installation procedures.

1) Remove the trunk side trim (sedan model) or luggage side mat (OUTBACK model). 2) Lift up the vehicle, and then remove the rear wheels. 3) Remove the nut, and disconnect the rear stabilizer link. 4) Remove the bolts at the bottom of the shock absorber. 5) Disconnect the rear lateral link.

RS-00260

E: INSPECTION Refer to “Front Strut” for inspection procedures.

F: DISPOSAL CAUTION: • Before handling the shock absorber, be sure to wear goggles to protect eyes from gas, oil and cutting powder. • Do not disassemble the shock absorber or place it into a fire. • Drill a hole into shock absorbers in case of discarding shock absorbers filled with gas. 1) Place the shock absorber on a level surface with the piston rod fully expanded. 2) Make a hole into the specified position 30 mm (1.18 in) deep using a drill with 2 — 3 mm (0.08 — 0.12 in) diameter.

6) Remove the nuts of the shock absorber mount.

(1) RS-00135

(1) 40 mm (1.57 in)

RS-00315

7) Remove the shock absorber.

B: INSTALLATION CAUTION: • Be sure to use a new self-locking nut. • Always tighten the bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground. 1) Install in the reverse order of removal.

Tightening torque: Refer to “COMPONENT” of “General Description” for the tightening torque. 2) Check the wheel alignment and adjust if necessary.

C: DISASSEMBLY Refer to “Front Strut” for disassembly procedure.

RS-14

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Front Lateral Link REAR SUSPENSION

7. Front Lateral Link

B: INSTALLATION

A: REMOVAL

CAUTION: • Be sure to use a new self-locking nut. • Always tighten the bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground. 1) Install in the reverse order of removal.

1) Lift up the vehicle, and then remove the rear wheels. 2) Remove the rear trailing link. 3) Remove the snap pin and nut. (1)

(2)

Tightening torque: Front lateral link to Sub frame 120 N·m (12.2 kgf-m, 88.5 ft-lb) Front lateral link to Rear axle housing 60 N·m (6.1 kgf-m, 44.3 ft-lb) 2) Inspect the wheel alignment and adjust if necessary.

C: DISASSEMBLY Using the ST A and ST B, press the bushing out. ST A 20099AE000 INSTALLER & REMOVER ST B 20099AE000 INSTALLER & REMOVER

RS-00189

(1) Snap pin (2) Nut

ST-A

4) Using a puller, remove the ball joint.

ST-B

RS-00192

D: ASSEMBLY RS-00190

5) Place an alignment mark on the front lateral link adjusting bolt and rear sub frame. 6) Remove the adjusting bolt, and remove the front lateral link. CAUTION: When removing the adjusting bolt, make sure to fix the bolt head in place, and loosen the nut.

Using the ST A and ST B, press-fit the bushing. ST A 20099AE000 INSTALLER & REMOVER ST B 20099AE000 INSTALLER & REMOVER CAUTION: Press-fit the bushing straight.

E: INSPECTION 1) Visually check the front lateral link for damage and deformation. 2) Visually check the bushing for abnormal cracks, damages or fatigue.

RS-00262

RS-15

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Rear Lateral Link REAR SUSPENSION

8. Rear Lateral Link

D: ASSEMBLY

A: REMOVAL

Using the ST A and ST B, press-fit the bushing. STA 20099AE010 INSTALLER & REMOVER STB 20099AE010 INSTALLER & REMOVER

1) Lift up the vehicle, and then remove the rear wheels. 2) Remove the nut, and remove the stabilizer link. 3) Remove the bolts at the bottom of the shock absorber. 4) Remove the bolt, and remove the rear lateral link.

ST-A

ST-B RS-00083

E: INSPECTION 1) Visually check the rear lateral link for damage and deformation. 2) Visually check the bushing for abnormal cracks, damages or fatigue.

RS-00263

B: INSTALLATION CAUTION: • Be sure to use a new self-locking nut. • Always tighten the bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground. 1) Install in the reverse order of removal.

Tightening torque: Rear lateral link 80 N·m (8.2 kgf-m, 59 ft-lb) Shock absorber 80 N·m (8.2 kgf-m, 59 ft-lb) Stabilizer link 33 N·m (3.4 kgf-m, 24.3 ft-lb) 2) Inspect the wheel alignment and adjust if necessary.

C: DISASSEMBLY Using the ST A and ST B, press the bushing out. STA 20099AE010 INSTALLER & REMOVER STB 20099AE010 INSTALLER & REMOVER

ST-A

ST-B RS-00083

RS-16

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Rear Sub Frame REAR SUSPENSION

9. Rear Sub Frame

10) Remove the rear ABS wheel speed sensor from the rear axle.

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift up the vehicle, and then remove the rear wheels. 3) Separate the front exhaust pipe and rear exhaust pipe. 4) Remove the rear exhaust pipe and muffler. 5) Remove the propeller shaft.

6) Remove the brake hose bracket.

CAUTION: • Be careful not to damage the sensor. • Do not apply excessive force to the sensor harness.

VDC00769

11) Remove the bolts at the bottom of the shock absorber.

RS-00264

7) Remove the rear disc brake caliper, and suspend it to the shock absorber.

RS-00267

12) Support the sub frame using a jack. 13) Remove the rear sub frame.

FU-03358

8) Disconnect the rear parking brake cable from the parking brake assembly. 9) Remove the rear ABS wheel speed sensor harness bracket from the upper arm. NOTE: Leave the sensor harness clamp on the vehicle side.

VDC00770

RS-17

FU-04094

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Rear Sub Frame REAR SUSPENSION

B: INSTALLATION CAUTION: • Be sure to use a new self-locking nut. • Always tighten the bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground. 1) Install in the reverse order of removal.

Tightening torque: Refer to “COMPONENT” of “General Description” for the tightening torque. 2) Bleed air from brake system. 3) Inspect the wheel alignment and adjust if necessary.

C: INSPECTION Check the removed parts for wear, damage and crack, and repair or replace them if faulty.

RS-18

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General Diagnostic Table REAR SUSPENSION

10.General Diagnostic Table A: INSPECTION 1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT Possible cause (1) Permanent distortion or damaged coil spring (2) Rough operation of shock absorber (3) Installation of the wrong shock absorber (4) Installation of the wrong coil spring

Corrective action Replace. Replace. Replace with proper parts. Replace with proper parts.

2. POOR RIDE COMFORT 1) Large rebound shock 2) Rocking of the vehicle continues too long after running over bump and hump. 3) Excessive shock in bumping Possible cause

Corrective action

(1) Damaged coil spring (2) Overinflation of tires (3) Improper wheel arch height (4) Defective operation of shock absorber (5) Damage or deformation of shock absorber mount (6) Unsuitable length (maximum or minimum) of shock absorber (7) Deformation or loss of bushing (8) Deformation or damage of helper in shock absorber (9) Oil leakage from the shock absorber

Replace. Adjust. Replace the coil springs with new parts. Replace. Replace. Replace with appropriate parts. Replace. Replace. Replace.

3. NOISE Possible cause (1) Wear or damage of shock absorber component parts (2) Loosening of the suspension link or arm installing bolt

Corrective action Replace. Tighten to the specified torque.

(3) Deformation or loss of bushing (4) Unsuitable length (maximum or minimum) of shock absorber (5) Damaged coil spring (6) Wear or damage of the ball joint (7) Deformation of the stabilizer clamp

Replace. Replace with appropriate parts. Replace. Replace. Replace.

RS-19

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General Diagnostic Table REAR SUSPENSION

RS-20

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WHEEL AND TIRE SYSTEM

WT 1. 2. 3. 4. 5.

Page General Description ...................................................................................2 Tire and Wheel ...........................................................................................4 “T-type” Tire ...............................................................................................6 Tire Pressure Monitoring System ...............................................................7 General Diagnostic Table ...........................................................................9

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General Description WHEEL AND TIRE SYSTEM

1. General Description A: SPECIFICATION

WT-00001

(1) Offset (2) P.C.D. Tire size

Wheel size

Offset mm (in)

P.C.D. mm (in)

Tire inflation pressure kPa (kgf/cm2, psi) Front wheel

Rear wheel

230 (2.3, 33)

220 (2.2, 32)

220 (2.2, 32)

210 (2.1, 31)

55 (2.17)

230 (2.3, 33)

220 (2.2, 32)

20 (0.79)



420 (4.2, 60)

61/

16 × 2JJ 16 × 61/2 J 17 × 71/2 J 17 × 71/2 J 16 × 61/2JJ 17 × 7J 18 × 71/2 J 16 × 4T

P205/60R16 91V P215/50R17 90V P225/50R17 93V P215/70R16 99S P225/60R17 98T 225/45R18 91W T135/80R16 101M T135/70R17 102M T145/80R17 97M

17 × 4T

48 (1.89) 100 (3.94)

NOTE: Size and inflation pressure of the standard equipment tire and spare tire for emergency are described on the “Tire inflation pressure” label attached to the body side of the driver’s door.

1. SERVICE DATA Part Steel wheel Aluminum wheel Wheel balancing Dynamic unbalance

Axial runout Radial runout 1.5 mm (0.059 in) 1.0 mm (0.039 in) Standard: Service limit 5 g (0.18 oz) or less

WT-2

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General Description WHEEL AND TIRE SYSTEM

B: COMPONENT T2

T1 (1)

(3)

(2) (4)

WT-00151

(1)

Tire inflation pressure monitor control module

(3)

Transmitter (snap-in type)

(2)

Screw

(4)

Valve

T1: 1.4 (0.14, 1) T2: 8 (0.8, 5.9)

C: PREPARATION TOOL 1. GENERAL TOOL TOOL NAME Air pressure gauge Dial gauge Wheel balancer

Tightening torque:N·m (kgf-m, ft-lb)

REMARKS Used for measuring tire air pressure. Used for measuring wheel runout. Used for adjusting wheel balance.

WT-3

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Tire and Wheel WHEEL AND TIRE SYSTEM

2. Tire and Wheel

2. TIRE ROTATION

A: REMOVAL

NOTE: Rotate tires periodically (12,500 km/7,500 miles) in order to prolong life and to prevent uneven wear. Rotate tires as shown in the figure depending on whether or not the direction of the tire rotation is specified. • When the direction of tire rotation is not specified

1) Remove the hubcap. (model with hubcap) 2) Lift up the vehicle. 3) Remove the wheel nut. 4) Remove the wheels. NOTE: When removing the wheels, be careful not to damage the hub bolts.

B: INSTALLATION 1) Install the wheels to the vehicle. 2) Tighten the wheel nuts to the specified torque.

1

Tightening torque: 120 N·m (12.2 kgf-m, 88.5 ft-lb)

C: INSPECTION

WT-00113

1. TIRE

(1) Front side of vehicle

CAUTION: When replacing a tire, make sure to use only tires of the same size, construction and load range as originally installed. 1) Tire size and tire inflation pressure check 2) Cracks, damage and wear check 3) Tire runout check (1) Lift up the vehicle. (2) Slowly rotate the wheel to check rim “runout” using a dial gauge.

• When the direction of tire rotation is specified

1

WT-00115

(1) Front side of vehicle

3. WHEEL BALANCING 1) Using the wheel balancer, measure wheel balance. 2) Adjust the wheel balancing. NOTE: • Unbalance after adjusting the wheel balancing should be 5 g (0.18 oz) or less. • When using the adhesive type weight, degrease the surface where the adhesive type weight will be applied securely. • After applying the adhesive type weight, apply a force to the weight and attain full adhesion.

WT-00004

• Aluminum wheel Axial runout limit Radial runout limit 1.0 mm (0.039 in)

• Steel wheel Axial runout limit Radial runout limit 1.5 mm (0.059 in)

(3) If the rim runout exceeds service limit, replace the wheel.

WT-4

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Tire and Wheel WHEEL AND TIRE SYSTEM

• Using the knock-on type weight, check the size of the knock-on part. A

A

(1)

(2)

WT-00107

(1) Knock-on type weight for aluminum wheel (2) Knock-on type weight for steel wheel

Service limit A: Knock-on type weight for steel wheel: 2.0 mm (0.079 in) Knock-on type weight for aluminum wheel: 5.0 mm (0.197 in)

WT-5

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“T-type” Tire WHEEL AND TIRE SYSTEM

3. “T-type” Tire A: NOTE “T-type” tire for temporary use is prepared as a spare tire. CAUTION: • The “T-type” tire is only for temporary use. Replace with a conventional tire as soon as possible. • Do not use tire chains for “T-type” tires. Doing so can damage the vehicle and the tires because the tires are too small in size to attach chains to. • Do not drive at a speed greater than 80 km/h (50 MPH). • Drive at as low a speed as possible and avoid bumps on the road.

B: REPLACEMENT Refer to “Tire & Wheel” for removal and installation of the “T-type” tire.

C: INSPECTION Refer to “Tire & Wheel” for inspection of the “Ttype” tire.

WT-6

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Tire Pressure Monitoring System WHEEL AND TIRE SYSTEM

4. Tire Pressure Monitoring System

B: INSTALLATION 1. TRANSMITTER (TIRE INFLATION PRESSURE SENSOR)

A: REMOVAL 1. TRANSMITTER (TIRE INFLATION PRESSURE SENSOR) 1) Remove the wheels from the vehicle. 2) Remove the tire from the wheel.

CAUTION: When installing, use new transmitter assembly or the transmitter equipped with new valve and screw. 1) When reusing the transmitter, replace the valve and screw with new parts and install.

CAUTION: When removing the tire from the wheel, use the tire changer. 3) Remove the screw, and remove the transmitter from the valve stem.

(1)

(2)

(3)

NOTE: When reusing the transmitter, replace the valve and screw with new parts. WT-00126 (3) (2)

(4)

(1) Screw (2) Transmitter (3) Valve

(1)

Tightening torque: 1.4 N·m (0.14 kgf-m, 1 ft-lb) 2) Align the transmitter with the valve hole, and install.

WT-00125

(1) (2) (3) (4)

NOTE: When using the jig which is used by hitching the root of the valve cap and pulling it out, use different short cap. 3) Install the tire to the wheel.

Wheel Transmitter Screw Valve

CAUTION: • When installing the tire to the wheel, use the tire changer.

4) Remove the valve from the wheel.

2. TIRE PRESSURE MONITORING CONTROL MODULE 1) Remove the driver’s seat. 2) Turn over the floor mat. 3) Remove the connector, and remove the tire inflation pressure monitor control module.

WT-00149

WT-7

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Tire Pressure Monitoring System WHEEL AND TIRE SYSTEM

• Set the tire changer boom to the position shown in the figure so as not to damage the transmitter. (4) (3)

(2)

(5) (6)

(1) WT-00130

(1) (2) (3) (4) (5) (6)

Transmitter Direction of the turn table rotation 135° Tire changer boom 90° Starting point where bead is inserted into the rim

4) Install the wheels to the vehicle. 5) Register the transmitter ID to the tire inflation pressure monitor control module.

2. TIRE PRESSURE MONITORING CONTROL MODULE Install in the reverse order of removal.

Tightening torque: 8 N·m (0.8 kgf-m, 5.9 ft-lb)

C: ADJUSTMENT If the transmitter is replaced, re-register the transmitter ID.

WT-8

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General Diagnostic Table WHEEL AND TIRE SYSTEM

5. General Diagnostic Table A: INSPECTION Symptoms The vehicle wobbles.

Possible cause Improper tire air pressure Tire uneven wear Front wheel alignment Rear wheel alignment Front strut Rear shock absorber Front axle Front hub unit bearing Rear hub unit bearing

The vehicle swings abnormally.

Improper tire air pressure Tire uneven wear Front stabilizer Front wheel alignment Rear wheel alignment

Abnormal wheel vibration

Improper tire air pressure Tire uneven wear Improper wheel balancing Front axle Front hub unit bearing Rear hub unit bearing

Abnormal wear of tire

Improper tire air pressure Improper wheel balancing Front wheel alignment Rear wheel alignment

WT-9

Corrective action Adjust the tire pressure. Check according to the “Abnormal wear of tire”, and repair it after performing action. Check the front wheels alignment. Check the rear wheels alignment. Check the front struts. Check the rear shock absorber. Check the front axle. Check the front hub unit bearings. Check the rear hub unit bearings. Adjust the tire pressure. Check according to the “Abnormal wear of tire”, and repair it after performing action. Check the front stabilizer. Check the front wheels alignment. Check the rear wheels alignment. Adjust the tire pressure. Check according to the “Abnormal wear of tire”, and repair it after performing action. Check the wheel balancing. Check the front axle. Check the front hub unit bearings. Check the rear hub unit bearings. Adjust the tire pressure. Check the wheel balancing. Check the front wheels alignment. Check the rear wheels alignment.

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General Diagnostic Table WHEEL AND TIRE SYSTEM

WT-10

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TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

TPM(diag) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Page Basic Diagnostic Procedure .......................................................................2 General Description ...................................................................................4 Electrical Component Location ..................................................................6 Control Module I/O Signal ..........................................................................7 Subaru Select Monitor ................................................................................8 Read Diagnostic Trouble Code (DTC) .....................................................11 Clear Memory Mode .................................................................................12 Read Current Data ...................................................................................13 Register Transmitter (ID) ..........................................................................14 Display Transmitter (ID) ...........................................................................15 Inspection Mode .......................................................................................16 Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern ...17 List of Diagnostic Trouble Code (DTC) ....................................................23 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................25 General Diagnostic Table .........................................................................34

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Basic Diagnostic Procedure TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

1. Basic Diagnostic Procedure A: PROCEDURE CAUTION: When removing or installing, remove all foreign matter (dust, water, and oil) from the tire inflation pressure monitoring control module connectors. NOTE: To check harness for open or short circuits, shake the suspected trouble spot or connector. 1

2

3

Step CHECK PRE-INSPECTION. 1) Ask the user from when the warning light is lit or blinking. 2) Before performing diagnostics, check the component which might affect the problems of tire inflation pressure monitoring system. CHECK DIAGNOSTIC TROUBLE CODE (DTC). 1) Turn the ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn the ignition switch to ON and run the Subaru Select Monitor. NOTE: If the communication function of the Subaru Select Monitor cannot be executed properly, check the communication circuit. 4) Read the DTC. PERFORM GENERAL DIAGNOSTICS. 1) Perform the inspection by referring to “General Diagnostic Table”. 2) Perform the Clear Memory Mode. 3) Perform the Inspection Mode. 4) Read the DTC. Check the DTC is not displayed.

Check Yes Is the component that might Go to step 2. influence the tire inflation pressure monitoring system problem normal?

No Repair or replace each component.

Is DTC displayed?

Go to step 4.

Does the inflation pressure warning light turn on upon IG ON and go off after approx. 2 seconds?

Finish the diagno- Check the tire inflasis. tion pressure warning light.

TPM(diag)-2

Go to step 3.

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Basic Diagnostic Procedure TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

4

Step PERFORM DIAGNOSIS. 1) Refer to “List of Diagnostic Trouble Code (DTC)”. 2) Correct the cause of trouble. 3) Perform the Clear Memory Mode. 4) Perform a driving test. Drive the vehicle at a speed of 40 km/h (25 MPH) or more for at least 10 minutes. 5) Read the DTC.

Check Is DTC displayed?

TPM(diag)-3

Yes No Repeat the steps 1 Finish the diagnoto 4 until DTC is not sis. shown.

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General Description TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

2. General Description

B: INSPECTION

A: CAUTION

Before performing diagnosis, check the following item which might affect the quality of the tire pressure monitoring system.

1. SUPPLEMENTAL RESTRAINT SYSTEM “AIRBAG” Airbag system wiring harness is routed near the TPM control module. CAUTION: • Do not use electrical test devices on any airbag system wiring harness circuits. • Be careful not to damage the airbag system wiring harness when servicing the tire inflation pressure monitoring control module.

2. TIRE PRESSURE MONITORING CONTROL MODULE • If a transmitter is replaced, the ID of the new transmitter must be registered. • When adjusting tire inflation pressure indoors in winter, there is a big temperature difference between the indoor facilities and outside. Once the car is outside where the temperature is lower, the air pressure in the tires will drop, causing the tire inflation pressure warning light to illuminate, even if the pressure in the tires was adjusted to standard values indoors. To avoid this, it is necessary to adjust the tire inflation pressure to the high side in consideration of the difference in temperature between inside and outside according to the following table. a. Sedan model Temperature °C (°F) Tire inflation pressure kPa (psi)

Indoor temperature Outdoor temperature

1. TIRE • Inspect that the tire pressure is within the specification while the tire is cool. (Refer to Tire Caution Label.) • Check the tires for damage or the insertion of foreign matters.

2. BATTERY Check that amount of battery fluid, gravity and voltage are within the specifications.

Standard voltage: 12 V or more Specific gravity: 1.260 or more

15.5 (60)

–1 (30)

–12 (10)

–23 (–10)

Front

250 (36)

265 (38)

280 (40)

Rear

240 (35)

255 (37)

270 (39)

b. OUTBACK model Temperature °C (°F) Tire inflation pressure kPa (psi)

Indoor temperature Outdoor temperature

15.5 (60)

–1 (30)

–12 (10)

–23 (–10)

Front

240 (35)

255 (37)

270 (39)

Rear

230 (33)

245 (35)

255 (37)

TPM(diag)-4

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General Description TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 1B022XU0

DESCRIPTION SUBARU SELECT MONITOR III KIT

REMARKS Used for troubleshooting the electrical system.

ST1B022XU0

2. GENERAL TOOL TOOL NAME Circuit tester Transmitter registration tool

REMARKS Used for measuring resistance, voltage and current. Used to register the transmitter ID. Manufacturer: Kent-Moore

TPM(diag)-5

Item number: J45295

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Electrical Component Location TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

3. Electrical Component Location A: LOCATION

(2)

(3)

(1) (3)

TPM00064

(1)

Tire inflation pressure monitoring control module

(2)

Tire inflation pressure warning light

(3)

Snap-in transmitter

(1)

(2) TPM00065

(3)

TPM00049

TPM(diag)-6

TPM00066

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Control Module I/O Signal TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

4. Control Module I/O Signal A: ELECTRICAL SPECIFICATION

TO

R211

6 5 4 3 2 1 12 11 10 9 8 7

TPM00067

Terminal No.

Measured value

Measuring condition

1

Select monitor communication

2

Tire inflation pressure warning light out- Light up when failure occurs or tire put inflation pressure decreases

4 5 6

Speed sensor signal Ignition power supply Battery power supply

8 9

Remarks

Serial communication

Traveling (pulse signal) IG switch ON (battery voltage) Battery voltage

Body integrated unit (hazard output signal) GND 0 V (constantly)



B: WIRING DIAGRAM

TPM(diag)-7

— System failure: Blink 25 cycles → Remain on Pressure decreases: Light up Vary with vehicle speed — Always When hazard warning light is lit Always

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Subaru Select Monitor TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

5. Subaru Select Monitor A: OPERATION For the operation procedure, refer to the “PC application help for Subaru Select Monitor”. NOTE: If the tire inflation pressure monitoring control module and Subaru Select Monitor can not communicate, check the communication circuit.

TPM(diag)-8

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Subaru Select Monitor TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

B: INSPECTION 1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE DETECTING CONDITION: Defective harness connector TROUBLE SYMPTOM: Communication is impossible between the tire inflation pressure monitoring control module and the Subaru Select Monitor. WIRING DIAGRAM: B40

TO POWER SUPPLY CIRCUIT FB-26 F/B FUSE NO. 4 (IG)

*1

FB-17 F/B FUSE NO. 7 (B)

*1

J/C

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 3, 4, 5 AND 6

i165

B40 16

i165

*1

20 i1

i2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1 2 3 4 5 6 7 8 9 10 11 12

7 B36

R211

DATA LINK CONNECTOR

5

7

i2 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

MB-42 M/B FUSE NO. 12 (B)

B36

R211

9

1

5

6

R339

TPMS CM

1

2

10 11

12

13

14 15 16 17 18 19 20 21 22 23 24 25 26

3

4

5

6

7

8

9

27

28

29 30 31 32 33 34 35 36 37 38 39 40 41 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

42

TPM00068

1

Step CHECK IGNITION SWITCH.

Check Is the ignition switch ON?

Yes Go to step 2.

2

CHECK BATTERY.

Is the voltage 11 V or more?

Go to step 3.

3

CHECK BATTERY TERMINAL.

4

5

No Turn the ignition switch to ON, and select TPM mode using Subaru Select Monitor. Charge or replace the battery. Go to step 4.

Is there poor contact at battery Repair or tighten terminal? the battery terminal. CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Go to step 8. Go to step 5. MUNICATION. on Subaru Select Monitor? 1) Turn the ignition switch to ON. 2) Using the Subaru Select Monitor, check whether communication to other systems can be executed normally. CHECK SUBARU SELECT MONITOR COM- Is the system name displayed Replace the tire Go to step 6. MUNICATION. on Subaru Select Monitor? inflation pressure 1) Turn the ignition switch to OFF. monitoring control 2) Disconnect the tire inflation pressure monimodule. toring control module connector. 3) Turn the ignition switch to ON. 4) Check whether communication to other systems can be executed normally.

TPM(diag)-9

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Subaru Select Monitor TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

6

7

8

9

10

11

12

Step CHECK HARNESS CONNECTOR BETWEEN EACH CONTROL MODULE AND DATA LINK CONNECTOR. 1) Turn the ignition switch to OFF. 2) Disconnect the tire inflation pressure monitoring control module. 3) Measure the resistance between data link connector and chassis ground. Connector & terminal (B40) No. 7 — Chassis ground: CHECK OUTPUT VOLTAGE FOR TIRE INFLATION PRESSURE MONITORING CONTROL MODULE. 1) Turn the ignition switch to ON. 2) Measure the voltage between the tire inflation pressure monitoring control module and chassis ground. Connector & terminal (B40) No. 7 (+) — Chassis ground (–): CHECK HARNESS BETWEEN TIRE INFLATION PRESSURE MONITORING CONTROL MODULE AND DATA LINK CONNECTOR. 1) Turn the ignition switch to OFF. 2) Measure the resistance between the tire inflation pressure monitoring control module and data link connector. Connector & terminal (R211) No. 1 — (B40) No. 7: CHECK TIRE INFLATION PRESSURE MONITORING CONTROL MODULE CONNECTOR.

Check Is the resistance 1 MΩ or more?

Yes Go to step 7.

No Repair the harness and connector between each control module and data link connector.

Is the voltage less than 1 V?

Go to step 8.

Repair the harness and connector between each control module and data link connector.

Is the resistance less than 0.5 Ω?

Go to step 9.

Repair the harness and connectors between the tire inflation pressure monitoring control module and data link connector.

CHECK POWER SUPPLY CIRCUIT. 1) Turn the ignition switch to ON. (engine OFF) 2) Measure the ignition power supply voltage between the tire inflation pressure monitoring control module and chassis ground. Connector & terminal (R211) No. 5 (+) — Chassis ground (–): CHECK HARNESS BETWEEN TIRE INFLATION PRESSURE MONITORING CONTROL MODULE AND CHASSIS GROUND. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from the tire inflation pressure monitoring control module. 3) Measure the resistance between the tire inflation pressure monitoring control module and chassis ground. Connector & terminal (R211) No. 9 — Chassis ground: CHECK POOR CONTACT OF CONNECTOR.

Is the voltage 10 — 15 V?

Go to step 11.

Is the resistance less than 0.5 Ω?

Go to step 12.

Is the tire inflation pressure Go to step 10. monitoring control module connector inserted to the module until it is locked securely?

Is there poor contact of the tire Repair the connector. inflation pressure monitoring control module power supply, ground circuit and data link connector?

TPM(diag)-10

Insert the tire inflation pressure monitoring control module connector to the tire inflation pressure monitoring control module. Repair the open circuit of harness between the tire inflation pressure monitoring control module and battery. Repair the open circuit of harness of the tire inflation pressure monitoring control module.

Replace the tire inflation pressure monitoring control module.

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Read Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

6. Read Diagnostic Trouble Code (DTC) A: OPERATION For the operation procedure, refer to the “PC application help for Subaru Select Monitor”. NOTE: • For details concerning DTCs, refer to List of Diagnostic Trouble Code (DTC). • All detected DTCs are displayed. • If a particular DTC is not stored in memory properly at the occurrence of problem (due to a drop in tire inflation pressure monitoring control module power supply etc.), the DTC suffixed with a question mark “?” is displayed on Subaru Select Monitor display screen. This shows it may be an unreliable reading. • When DTC is not displayed, check the indicator circuit and the communication circuit.

TPM(diag)-11

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Clear Memory Mode TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

7. Clear Memory Mode A: OPERATION For the operation procedure, refer to the “PC application help for Subaru Select Monitor”.

TPM(diag)-12

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Read Current Data TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

8. Read Current Data A: OPERATION For the operation procedure, refer to the “PC application help for Subaru Select Monitor”.

B: LIST Display Tire 1 FN code

Contents to be displayed

Tire 2 FN code Tire 3 FN code LEARN, LOW BAT, OFF, WAKE, RE ME, NORMAL Tire 4 FN code

Tire 1 air pressure Tire 2 air pressure Tire 3 air pressure Tire 4 air pressure

Value converted to tire pressure from data delivered from transmitter is displayed. (The figure may differ from the actual measured values.)

Unit of measure LEARN: Transmitted transmitter ID using the transmitter registration tool LOW BAT: Transmitter battery voltage running low OFF: Transmitter function stops (no data transmission) RE ME: Tire air changes ±8.4 kPa WAKE: When data transmission is started from a stopped state. NORMAL: Conditions other than above kPa, psig, mmHg, inHg kPa, psig, mmHg, inHg kPa, psig, mmHg, inHg kPa, psig, mmHg, inHg

Vehicle Speed

Vehicle speed signal which is input in control module

km/h, MPH

Pressure warning

Threshold where tire pressure warning light illuminates

kPa, psig, mmHg, inHg

Return pressure

Threshold where tire pressure warning light goes out

kPa, psig, mmHg, inHg

TPM(diag)-13

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Register Transmitter (ID) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

9. Register Transmitter (ID) A: OPERATION Transmitter registration is required in the following cases. • A transmitter is replaced. • Tire inflation pressure monitoring control module is replaced. NOTE: • If registration of the transmitter ID is not possible after two attempts, replace the tire inflation pressure monitoring control module. • During the registration, turn the ignition switch to OFF and end the Subaru Select Monitor. Or if the registration is not performed for 5 minutes or more, the registration mode is cancelled. • When rotating tires, there is no effect on the performance or functions of the tire inflation pressure monitoring control module even if the transmitter (ID) is not registered, however, the tire position displayed on the Subaru Select Monitor will be incorrect. 1) Adjust all tire inflation pressures to the specifications. 2) Connect Subaru Select Monitor and select the {2. Each System Check} on the «Main Menu». 3) On the «System Selection Menu» display, select the {Tire pressure monitor}. 4) After the {Tire pressure monitor} is displayed, select [OK]. 5) On the «Tire pressure monitor diagnosis» display, select the {Transmitter ID regist confirm}. 6) {ID registration mode When execute Registered ID is deleted. Continue?} is displayed, select [OK]. 7) Touch the transmitter registration tool to the side wall area near the air valve on the front left tire, and press the switch. The transmitter ID is sent to the tire inflation pressure monitoring control module. (At that time, the tire inflation pressure warning light blinks to confirm that the registration has started.)

NOTE: • The registration order of transmitter ID is not specified. • The transmitter registration tool is used by touching the side wall area near the transmitter. • When registration of each tire is completed, the hazard light will blink and {ID registration completed} is displayed on the Select Monitor screen. • If registration procedure stops in the halfway (turning ignition switch to OFF, wrong registration order, etc), proceed from step 5). 8) When ID registration is completed, the tire inflation pressure warning light remains lit for approximately 2 seconds, to end the registration. Switch to the screen displaying the transmitter ID on the Subaru Select Monitor display. 9) Check the transmitter ID that was registered, then perform a driving test.

(1)

(2) TPM00006

(1) Air valve (transmitter) (2) Transmitter registration tool

TPM(diag)-14

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Display Transmitter (ID) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

10.Display Transmitter (ID) A: OPERATION For the operation procedure, refer to the “PC application help for Subaru Select Monitor”.

TPM(diag)-15

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Inspection Mode TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

11.Inspection Mode A: PROCEDURE Reproduce the malfunction occurrence condition as much as possible. Drive the vehicle at 40 km/h (25 MPH) or faster for at least ten minutes.

TPM(diag)-16

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Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

12.Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern A: INSPECTION (4) (3)

(1)

(3) (2)

(2)

(6) (5)

(7) (10) (10) (9)

(9) (8) (19)

(13)

(12)

(11) (10)

(16)

(19)

(15)

(14)

(17)

(18)

(19) TPM00071

(1)

Ignition switch

(8)

(2) (3) (4) (5) (6) (7)

OFF ON Start Tire inflation pressure condition Within standard value Less than standard value (For the pressure warning level, refer to “CURRENT DATA”.)

(9) (10) (11) (12) (13) (14)

Tire inflation pressure warning light (pressure condition) Light OFF Light ON System condition Normal operation Faulty Tire inflation pressure warning light (system condition)

TPM(diag)-17

(15)

Light OFF

(16) (17) (18) (19)

Blink 1 second 25 blinking 2 seconds

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Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

1) If the tire inflation pressure warning light does not illuminate in accordance with this illumination pattern, there must be an electrical malfunction. 2) If the tire inflation pressure warning light does not go off, check the tire inflation pressure monitoring control module/warning light circuits and the combination meter circuit. NOTE: If the problem is fixed while driving at approximately 40 km/h (25 MPH) after the tire inflation pressure warning light blinks/lights, the warning light goes out and the tire inflation pressure monitoring system operates normally. (If there is a decrease in tire inflation pressure, or a malfunction of the system, the malfunction history is displayed.)

TPM(diag)-18

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Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

B: TIRE PRESSURE WARNING LIGHT DOES NOT COME ON DETECTING CONDITION: Defective combination meter TROUBLE SYMPTOM: When the ignition switch is turned to ON (engine OFF), the tire inflation pressure warning light does not come on (for approximately 2 seconds). WIRING DIAGRAM: B40

TO POWER SUPPLY CIRCUIT FB-26 F/B FUSE NO. 4 (IG)

FB-30 F/B FUSE NO. 5 (IG)

*1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 3, 4, 5 AND 6

19

FB-17 F/B FUSE NO. 7 (B)

*1

i165

I/F

J/C

MICRO COMPUTER

COMBINATION METER DRIVE CIRCUIT

i10

I/F

i2

1

*1

1 2 3 4 5 6 7 8 9 10 11 12

TIRE INFLATION PRESSURE WARNING LIGHT

i165

R211

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

6

7

16

i2 R339

9

2

5

6

i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 R211

TPMS CM

TPM00069

1

Step Check CHECK DIAGNOSTIC TROUBLE CODE Is diagnostics code (DTC) dis(DTC). played? Read the DTC by connecting the Subaru Select Monitor.

TPM(diag)-19

Yes Perform the diagnosis according to DTC.

No Replace the combination meter.

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Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

C: TIRE PRESSURE WARNING LIGHT DOES NOT COME OFF DETECTING CONDITION: • Defective combination meter • Tires inflation pressure drop • Transmitter ID not registered TROUBLE SYMPTOM: Tire inflation pressure warning light remains illuminating after engine starts. WIRING DIAGRAM: B40

TO POWER SUPPLY CIRCUIT FB-26 F/B FUSE NO. 4 (IG)

FB-30 F/B FUSE NO. 5 (IG)

*1

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 3, 4, 5 AND 6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

19

FB-17 F/B FUSE NO. 7 (B)

*1

i165

I/F

J/C

MICRO COMPUTER

COMBINATION METER DRIVE CIRCUIT

i10

I/F

i2

1

*1

1 2 3 4 5 6 7 8 9 10 11 12

TIRE INFLATION PRESSURE WARNING LIGHT

i165

R211

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

6

7

16

i2 R339

9

2

5

6

i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 R211

TPMS CM

TPM00069

1

2

3

Step Check CHECK DIAGNOSTIC TROUBLE CODE Is DTC displayed? (DTC). Read the DTC by connecting the Subaru Select Monitor.

Yes No Perform the diag- Go to step 2. nosis according to DTC. CHECK TRANSMITTER (ID). Is the transmitter ID registered? Go to step 3. Register the transDisplay the transmitter ID of the tire inflation mitter ID. CHECK TRANSMITTER DATA OUTPUT. Is the warning light output ON? Replace the tire Replace the com1) Select data display of the tire inflation presinflation pressure bination meter. sure monitoring. monitoring control

TPM(diag)-20

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Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

D: TIRE PRESSURE WARNING LIGHT IS 25 TIMES BLINKING AND TURN ON DETECTING CONDITION: • Tire inflation pressure monitoring control module is faulty. • Defective harness • Transmitter is faulty. TROUBLE SYMPTOM: Every time the engine starts, tire inflation pressure warning light blinks 25 times and then illuminates. WIRING DIAGRAM: B40

TO POWER SUPPLY CIRCUIT FB-26 F/B FUSE NO. 4 (IG)

FB-30 F/B FUSE NO. 5 (IG)

*1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 1, 2, 3, 4, 5 AND 6

19

FB-17 F/B FUSE NO. 7 (B)

*1

i165

I/F

J/C

MICRO COMPUTER

COMBINATION METER DRIVE CIRCUIT

i10

I/F

i2

1

*1

1 2 3 4 5 6 7 8 9 10 11 12

TIRE INFLATION PRESSURE WARNING LIGHT

i165

R211

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

6

7

16

i2 R339

9

2

5

6

i10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 R211

TPMS CM

TPM00069

1

2

Step Check CHECK DIAGNOSTIC TROUBLE CODE Is diagnostics code (DTC) dis(DTC). played? Read the DTC by connecting the Subaru Select Monitor. CHECK HARNESS. Is the voltage 10 V or more? 1) Connect the Subaru Select Monitor to the terminal No. 2 of the tire inflation pressure monitoring control module connector (R211). Connector & terminal (R211) No. 2 (+) — Chassis ground (–): 2) Turn the ignition switch to ON, and select “Oscilloscope” from the Main Menu of Subaru Select Monitor. 3) Check the voltage displayed.

TPM(diag)-21

Yes No Perform the diag- Go to step 2. nosis according to DTC. Go to step 3. Go to step 4.

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Tire Pressure Warning Light / Trouble Indicator Light Illumination Pattern TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

3

Step Check CHECK HARNESS. Is the pattern the same output 1) Check the output waveform displayed in the waveform as shown in the figoscilloscope of Subaru Select Monitor. ure? (1) 400±20 ms Duty 50 % High: Battery voltage Low: 1.5 V or less

Yes Check the combination meter.

No Replace the tire inflation pressure monitoring control module.

Replace the tire inflation pressure monitoring control module.

The harness between the combination meter connector and the tire inflation pressure monitoring control module connector is shorted or open. Repair or replace the harness.

High

Low (1) TPM00044

4

CHECK HARNESS. Is the voltage 10 V or more? 1) Disconnect the tire inflation pressure monitoring control module connector. 2) Connect the Subaru Select Monitor to the terminal No. 2 of the tire inflation pressure monitoring control module connector (R211). Connector & terminal (R211) No. 2 (+) — Chassis ground (–): 3) Turn the ignition switch to ON, and select “Oscilloscope” from the Main Menu of Subaru Select Monitor. 4) Check the voltage displayed.

TPM(diag)-22

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List of Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

13.List of Diagnostic Trouble Code (DTC) A: LIST DTC

Item

Contents of diagnosis

Remarks



11

Tire 1 Air Pressure Decrease

Tire pressure of tire 1 is reduced.

12

Tire 2 Air Pressure Decrease

Tire pressure of tire 2 is reduced.

13

Tire 3 Air Pressure Decrease

Tire pressure of tire 3 is reduced.

14

Tire 4 Air Pressure Decrease

Tire pressure of tire 4 is reduced.

Transmitter 1 No Data

Data cannot be received from transmitter 1.

22

Transmitter 2 No Data

Data cannot be received from transmitter 2.

23

Transmitter 3 No Data

Data cannot be received from transmitter 3.

24

Transmitter 4 No Data

Data cannot be received from transmitter 4.

31

Transmitter 1 Pressure Data Abnormal

Transmitter 1 data contents are abnormal.

32

Transmitter 2 Pressure Data Abnormal

Transmitter 2 data contents are abnormal.

33

Transmitter 3 Pressure Data Abnormal

Transmitter 3 data contents are abnormal.

34

Transmitter 4 Pressure Data Abnormal

Transmitter 4 data contents are abnormal.

41

Transmitter 1 Function Code Abnormal

Function code has error.

21

TPM(diag)-23



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List of Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS) DTC

Item

42

Transmitter 2 Function Code Abnormal

43

Transmitter 3 Function Code Abnormal

44

Transmitter 4 Function Code Abnormal

Contents of diagnosis Function code has error.

Function code has error.

Function code has error.

51

Transmitter 1 Battery Voltage Decrease

Transmitter battery voltage is low.

52

Transmitter 2 Battery Voltage Decrease

Transmitter battery voltage is low.

53

54

61

Remarks



Transmitter battery voltage is low.

Transmitter 4 Battery Voltage Decrease

Transmitter battery voltage is low.

Vehicle Speed is Abnormal

Vehicle speed signal is not input to the control module when the vehicle speed is 6 km/h (3.7 MPH) or more.

Transmitter 3 Battery Voltage Decrease

TPM(diag)-24

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

14.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC 11 TIRE 1 AIR PRESSURE DECREASE NOTE: Refer to DTC 14 for diagnostic procedure.

B: DTC 12 TIRE 2 AIR PRESSURE DECREASE NOTE: Refer to DTC 14 for diagnostic procedure.

C: DTC 13 TIRE 3 AIR PRESSURE DECREASE NOTE: Refer to DTC 14 for diagnostic procedure.

TPM(diag)-25

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

D: DTC 14 TIRE 4 AIR PRESSURE DECREASE DTC DETECTING CONDITION: Inflation pressure of tires dropped below the specified value. NOTE: For the specifications, refer to “CURRENT DATA”. TROUBLE SYMPTOM: Tire inflation pressure warning light illuminates. 1

2 3

4

Step CHECK TIRES. Lift up the vehicle and check for damage in the tires. CHECK TIRES. Check the tire inflation pressure. CHECK TRANSMITTER. Drive the vehicle at 40 km/h (25 MPH) or faster and compare the data from the transmitters on the four wheels. PERFORM DRIVING TEST. 1) Perform the Clear Memory Mode. 2) Perform the driving test. 3) Read diagnostic trouble code (DTC).

Check Are there cracks or damage?

Yes Replace the tire.

No Go to step 2.

Go to step 3. Adjust the tire inflaIs the tire inflation pressure within the specified value? tion pressure. Is there a transmitter with differ- Replace the trans- Go to step 4. ent data? mitter (tire inflation pressure sensor). Is DTC displayed?

Inspect using Finish the diagno“Diagnostic Proce- sis. dure with Diagnostic Trouble Code (DTC)”.

CAUTION: When driving vehicle to perform driving test, there should be always 2 persons (driver and checker) to check.

E: DTC 21 TRANSMITTER 1 NO DATA NOTE: Refer to DTC 24 for diagnostic procedure.

F: DTC 22 TRANSMITTER 2 NO DATA NOTE: Refer to DTC 24 for diagnostic procedure.

G: DTC 23 TRANSMITTER 3 NO DATA NOTE: Refer to DTC 24 for diagnostic procedure.

TPM(diag)-26

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

H: DTC 24 TRANSMITTER 4 NO DATA DTC DETECTING CONDITION: Data from transmitters cannot be received for 8 minutes TROUBLE SYMPTOM: Tire inflation pressure warning light blinks 25 times and then illuminates. 1

2

3

4

5

6

7

8

9 10

Step Check START FL TRANSMITTER. Is “Latest reception ID” 1) Connect the Subaru Select Monitor and updated? then turn the ignition switch to ON. 2) Select “Transmitter ID display”. 3) Use the transmitter registration tool and transmit the ID from the FL transmitter to check “Latest reception ID”. CHECK FL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 1 registered ID. START FR TRANSMITTER. Is “Latest reception ID” Use the transmitter registration tool and trans- updated? mit the ID from the FR transmitter to check “Latest reception ID”. Are the two IDs same? CHECK FR TRANSMITTER ID. Check the ID displayed in the updated ID display and the tire 2 registered ID. START RR TRANSMITTER. Is “Latest reception ID” Use the transmitter registration tool and trans- updated? mit the ID from the RR transmitter to check “Latest reception ID”. CHECK RR TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 3 registered ID. START RL TRANSMITTER. Is “Latest reception ID” Use the transmitter registration tool and trans- updated? mit the ID from the RL transmitter to check “Latest reception ID”. CHECK RL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 4 registered ID. CHECK MALFUNCTION TRANSMITTER.

Is ID recorded by this procedure? CHECK MALFUNCTION TRANSMITTER. Is the checked ID included in Check the registered ID of the transmitter indi- the record? cated by diagnostic trouble code (DTC).

Yes Go to step 2.

No Replace front left transmitter.

Go to step 3.

Record the received ID update as the FL transmitter. Go to step 3. Replace front right transmitter.

Go to step 4.

Go to step 5.

Go to step 6.

Go to step 7.

Go to step 8.

Go to step 9.

Go to step 10.

Record the received ID update as the FR transmitter. Go to step 5. Replace RR transmitter.

Record the received ID update as the RR transmitter. Go to step 7. Replace RL transmitter.

Record the received ID update as the RL transmitter. Go to step 9. Go to step 1.

Replace the trans- Replace the transmitter of the mitter showing the recorded position. latest ID that is not included in the registered IDs.

CAUTION: When driving vehicle to perform driving test, there should be always 2 persons (driver and checker) to check.

TPM(diag)-27

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

I:

DTC 31 TRANSMITTER 1 PRESSURE DATA ABNORMAL

NOTE: Refer to DTC 34 for diagnostic procedure.

J: DTC 32 TRANSMITTER 2 PRESSURE DATA ABNORMAL NOTE: Refer to DTC 34 for diagnostic procedure.

K: DTC 33 TRANSMITTER 3 PRESSURE DATA ABNORMAL NOTE: Refer to DTC 34 for diagnostic procedure.

TPM(diag)-28

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

L: DTC 34 TRANSMITTER 4 PRESSURE DATA ABNORMAL DTC DETECTING CONDITION: • When comparing the data from each transmitter with the previous data, the change is large. • The pressure exceeds what the transmitter can measure. (Excessive pressure) TROUBLE SYMPTOM: Tire inflation pressure warning light blinks 25 times and then illuminates. 1

2

3

4

5

6

7

8

9 10

Step Check START FL TRANSMITTER. Is “Latest reception ID” 1) Connect the Subaru Select Monitor and updated? then turn the ignition switch to ON. 2) Select “Transmitter ID display”. 3) Use the transmitter registration tool and transmit the ID from the FL transmitter to check “Latest reception ID”. CHECK FL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 1 registered ID. START FR TRANSMITTER. Is “Latest reception ID” Use the transmitter registration tool and trans- updated? mit the ID from the FR transmitter to check “Latest reception ID”. Are the two IDs same? CHECK FR TRANSMITTER ID. Check the ID displayed in the updated ID display and the tire 2 registered ID. START RR TRANSMITTER. Is “Latest reception ID” Use the transmitter registration tool and trans- updated? mit the ID from the RR transmitter to check “Latest reception ID”. CHECK RR TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 3 registered ID. START RL TRANSMITTER. Is “Latest reception ID” Use the transmitter registration tool and trans- updated? mit the ID from the RL transmitter to check “Latest reception ID”. CHECK RL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 4 registered ID. CHECK MALFUNCTION TRANSMITTER.

Is ID recorded by this procedure? CHECK MALFUNCTION TRANSMITTER. Is the checked ID included in Check the registered ID of the transmitter indi- the record? cated by diagnostic trouble code (DTC).

TPM(diag)-29

Yes Go to step 2.

No Replace front left transmitter.

Go to step 3.

Record the received ID update as the FL transmitter. Go to step 3. Replace front right transmitter.

Go to step 4.

Go to step 5.

Go to step 6.

Go to step 7.

Go to step 8.

Go to step 9.

Go to step 10.

Record the received ID update as the FR transmitter. Go to step 5. Replace RR transmitter.

Record the received ID update as the RR transmitter. Go to step 7. Replace RL transmitter.

Record the received ID update as the RL transmitter. Go to step 9. Go to step 1.

Replace the trans- Replace the transmitter showing the mitter of the recorded position. latest ID that is not included in the registered IDs.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

M: DTC 41 TRANSMITTER 1 FUNCTION CODE ABNORMAL NOTE: Refer to DTC 44 for diagnostic procedure.

N: DTC 42 TRANSMITTER 2 FUNCTION CODE ABNORMAL NOTE: Refer to DTC 44 for diagnostic procedure.

O: DTC 43 TRANSMITTER 3 FUNCTION CODE ABNORMAL NOTE: Refer to DTC 44 for diagnostic procedure.

TPM(diag)-30

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

P: DTC 44 TRANSMITTER 4 FUNCTION CODE ABNORMAL DTC DETECTING CONDITION: Unexpected function codes received from each transmitter. TROUBLE SYMPTOM: Tire inflation pressure warning light blinks 25 times and then illuminates. 1

2

3

4

5

6

7

8

Step Check START FL TRANSMITTER. Is “Latest reception ID” 1) Connect the Subaru Select Monitor and updated? then turn the ignition switch to ON. 2) Select “Transmitter ID display”. 3) Use the transmitter registration tool and transmit the ID from the FL transmitter to check “Latest reception ID”. CHECK FL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 1 registered ID. START FR TRANSMITTER. Is “Latest reception ID” Use the transmitter registration tool and trans- updated? mit the ID from the FR transmitter to check “Latest reception ID”. Are the two IDs same? CHECK FR TRANSMITTER ID. Check the ID displayed in the updated ID display and the tire 2 registered ID. START RR TRANSMITTER. Is “Latest reception ID” Use the transmitter registration tool and trans- updated? mit the ID from the RR transmitter to check “Latest reception ID”. CHECK RR TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 3 registered ID. START RL TRANSMITTER. Is “Latest reception ID” Use the transmitter registration tool and trans- updated? mit the ID from the RL transmitter to check “Latest reception ID”. CHECK RL TRANSMITTER ID. Are the two IDs same? Check the ID displayed in the updated ID display and the tire 4 registered ID.

9

CHECK MALFUNCTION TRANSMITTER.

10

Is the checked ID included in CHECK MALFUNCTION TRANSMITTER. Check the registered ID of the transmitter indi- the record? cated by diagnostic trouble code (DTC).

Is ID recorded by this procedure?

TPM(diag)-31

Yes Go to step 2.

No Replace front left transmitter.

Go to step 3.

Record the received ID update as the FL transmitter. Go to step 3. Replace front right transmitter.

Go to step 4.

Go to step 5.

Go to step 6.

Go to step 7.

Go to step 8.

Go to step 9.

Record the received ID update as the FR transmitter. Go to step 5. Replace RR transmitter.

Record the received ID update as the RR transmitter. Go to step 7. Replace RL transmitter.

Record the received ID update as the RL transmitter. Go to step 9. Go to step 10. Replace the transmitter indicated by diagnostics trouble code (DTC). Replace the trans- Replace the transmitter indicated by mitter of the recorded position. diagnostics trouble code (DTC).

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

Q: DTC 51 TRANSMITTER 1 BATTERY VOLTAGE DECREASE NOTE: Refer to DTC 54 for diagnostic procedure.

R: DTC 52 TRANSMITTER 2 BATTERY VOLTAGE DECREASE NOTE: Refer to DTC 54 for diagnostic procedure.

S: DTC 53 TRANSMITTER 3 BATTERY VOLTAGE DECREASE NOTE: Refer to DTC 54 for diagnostic procedure.

T: DTC 54 TRANSMITTER 4 BATTERY VOLTAGE DECREASE DTC DETECTING CONDITION: Received low battery signals 20 times from each transmitter. TROUBLE SYMPTOM: Tire inflation pressure warning light blinks 25 times and then illuminates. 1

Step Check CHECK TRANSMITTER. Is the fault eliminated? 1) Replace all transmitters with new parts and register their IDs. 2) Perform the Clear Memory Mode, and perform driving test.

TPM(diag)-32

Yes No Internal battery of Replace the tire the transmitter had inflation pressure worn out. monitoring control module.

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Diagnostic Procedure with Diagnostic Trouble Code (DTC) TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

U: DTC 61 VEHICLE SPEED IS ABNORMAL DTC DETECTING CONDITION: Vehicle speed function codes were received from the transmitter, but the vehicle speed signal was not input to the module. TROUBLE SYMPTOM: Tire inflation pressure warning light blinks 25 times and then illuminates. WIRING DIAGRAM: TO POWER SUPPLY CIRCUIT

*1 *2

FB-30 F/B FUSE NO. 5 (IG)

i10

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 10, 11 AND 12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

: TERMINAL No. OPTIONAL ARRANGEMENT AMONG 7, 8 AND 9

i165

R211

i165

J/C

POWER SUPPLY CIRCUIT

*2

SPEEDOMETER I/F

1 2 3 4 5 6 7 8 9 10 11 12

*1

i10

I/F

*1

19

29

i166

i2

i166

i165

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

i2

i1

B310

36

15

MICRO COMPUTER

R339

COMBINATION METER

B36

1

2 3 4 5 6 7 8 9 10 11 12 13

B36 6

11

4

9

14 15 16 17 18 19 20 21 22 23 24 25 26

TPMS CM

VDC CM

R211

B310

1

2

10 11

12

13

14 15 16 17 18 19 20 21 22 23 24 25 26

3

4

5

6

7

8

9

27

28

29 30 31 32 33 34 35 36 37 38 39 40 41 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

42

TPM00070

1

2

Step CHECK TIRE INFLATION PRESSURE MONITORING CONTROL MODULE. 1) Connect an oscilloscope to the terminal No. 4 of the tire inflation pressure monitoring control module connector (R211). 2) Lift up the vehicle and check the vehicle speed signal when the vehicle runs at 40 km/h (25 MPH). CHECK HARNESS. 1) Disconnect the combination meter connector (i10). 2) Connect a circuit tester to the tire inflation pressure monitoring control module connector (R211) and combination meter connector (i10), and measure the resistance. Connector & terminal (R211) No. 4 — (i10) No. 29:

Check Is the vehicle speed being input?

Yes No Replace the tire Go to step 2. inflation pressure monitoring control module.

Is the resistance less than 0.5 Ω?

Check the combi- Repair or replace nation meter.

TPM(diag)-33

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General Diagnostic Table TIRE PRESSURE MONITORING SYSTEM (DIAGNOSTICS)

15.General Diagnostic Table A: INSPECTION Symptoms Tire pressure warning light illumiTire pressure is reduced. nates. Tire pressure warning light blinks 25 times and then illuminates.

Tire pressure monitoring system has malfunction.

Tire pressure is dropping but the warning light does not illuminate.

Tire pressure warning light does not illuminate.

Problem parts • • • • • • • • • •

Improper tire pressure adjustment. Punctured tire Air pressure sensor malfunction Air pressure sensor is out of battery. Tire pressure monitoring control module is faulty. Defective vehicle harness Defective combination meter Air pressure sensor is faulty. Tire pressure monitoring control module is faulty. Defective combination meter

TPM(diag)-34

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DIFFERENTIALS

DI 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Page General Description ...................................................................................2 Differential Gear Oil ..................................................................................23 Front Differential Assembly ......................................................................25 Rear Differential (T-type) ..........................................................................26 Rear Differential (VA-type) .......................................................................45 Rear Differential Front Oil Seal ................................................................72 Rear Differential Side Oil Seal .................................................................74 Rear Differential Front Member ................................................................75 Rear Differential Mount Bushing ..............................................................76 Rear Differential Inspection Mode ............................................................78 General Diagnostic Table .........................................................................80

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General Description DIFFERENTIALS

1. General Description A: SPECIFICATION 1. REAR DIFFERENTIAL When replacing a rear differential assembly, select the correct one according to the following table. NOTE: Using a different rear differential assembly will cause the drive train and tires to drag or emit abnormal noise. Sedan Model

Rear differential type Identification LSD type Type of gear Gear ratio (Number of gear teeth) Oil capacity Rear differential gear oil

2.5L SOHC CVT VA1-type XD

6MT T-type T2

3.700 (37/10) 4.111 (37/9)

OUTBACK

2.5 L DOHC turbo 6MT T-type B1

3.6 L 5AT VA2-type XC — Hypoid gear

2.5L SOHC CVT T-type B2

6MT T-type TP

3.6 L 5AT VA2-type XC

4.111 (37/9) 3.083 (37/12) 3.900 (39/10) 4.444 (40/9) 3.083 (37/12) 0.8 2 (0.8 US qt, 0.7 Imp qt) GL–5 (75W–90)

DI-2

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General Description DIFFERENTIALS

2. IDENTIFICATION

3. REAR DIFFERENTIAL GEAR OIL

Identification positions are shown in the following figures. For details concerning identification, refer to the “ID” section. • T-type

Recommended gear oil: GL–5 (75W–90) CAUTION: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.

(1)

( C) ( F)

(1) (2) (3) GL-5 (4) -30 -26 -15 -5 0 -22 -15 5 23 32

15 59

25 30 77 86 90

85W 80W 75W -90

DI-00502

(1) Identification

MT-00001

(1) (2) (3) (4)

• VA1-type

(1)

ID-00312

(1) Identification

• VA2-type

(1)

DI-00607

(1) Identification

DI-3

Item Rear differential gear oil API classification SAE viscosity No. and applicable temperature

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General Description DIFFERENTIALS

4. SERVICE DATA T-type VA-type T-type Measured with torque wrench N·m (kgf-m, ft-lb) VA-type T-type Side gear backlash mm (in) VA1-type VA2-type Side bearing standard width mm (in) T-type Hypoid driven gear to drive pinion backlash mm (in) VA-type Hypoid driven gear runout on its back surface mm (in) Drive pinion bearing preload (For new bearing)

Measured with spring measurement (measured at companion flange bolt hole) N (kgf, lbf)

DI-4

17.7 — 38.8 (1.8 — 4.0, 4.0 — 8.7) 12.7 — 32.2 (1.3 — 3.3, 2.9 — 7.2) 0.67 — 1.47 (0.07 — 0.15, 0.49 — 1.08) 0.48 — 1.22 (0.05 — 0.12, 0.35 — 0.90) 0.10 — 0.20 (0.004 — 0.008) 0.05 — 0.15 (0.002 — 0.006) 0.13 — 0.18 (0.005 — 0.007) 20.00 (0.7874) 0.10 — 0.20 (0.004 — 0.008) 0.10 — 0.15 (0.004 — 0.006) 0.05 (0.002)

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General Description DIFFERENTIALS

B: COMPONENT 1. REAR DIFFERENTIAL (T-TYPE) (1)

(18) (19)

(21) (20)

(2) (3) (4)

(19)

(5)

(20) (23)

(1)

(18)

(21) (22) (25) (26)

T4

(27)

T1 (16)

(28)

T3 T3

(15) (24)

(14)

(30)

T2

(23)

(13) (17)

(29)

(31)

(6) (7)

T1 (13) (14) (15) (8) (16)

(9) T5

(17)

(10) (11) (12)

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Hypoid driven gear and drive pinion set Pinion height adjusting washer Rear bearing Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier Front bearing SPACER Pilot bearing Front oil seal Companion flange Self-locking nut Side bearing

DI-00586

(14)

O-ring

(27)

Oil filler plug

(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26)

Side retainer shim Side retainer Side oil seal Side gear thrust washer Side gear Pinion mate gear Pinion mate gear washer Pinion shaft lock pin Snap ring Pinion mate shaft Air breather cap Stud bolt

(28) (29) (30) (31)

Oil drain plug Rear cover Differential case Gasket

DI-5

Tightening torque:N·m (kgf-m, ft-lb) T1: 10.5 (1.1, 7.7) T2: 29.5 (3.0, 21.8) T3: 49 (5.0, 36.1) T4: 103 (10.5, 76.0) T5: 181.5 (18.5, 133.9)

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General Description DIFFERENTIALS

2. REAR DIFFERENTIAL (VA1-TYPE) (18) (19)

(20)

(1) (19)

(18)

(2) (3) (4) T3

(5)

(21)

(17) (16)

(23)

(15)

(22)

(14) (25)

T2

(30) (24) (27)

T1 (26)

(28)

(13) (6) (26)

(7) (29)

T1

(13)

T1

(14) (15)

(8)

(16) (17)

(9) T4

(10) (11) (12)

(1)

DI-00635

(13)

Lock plate

(25)

Stud bolt

(2) (3)

Hypoid driven gear and drive pinion set Pinion height adjusting washer Rear bearing

(14) (15)

Side bearing O-ring

(26) (27)

Gasket Oil filler plug

(4) (5) (6) (7) (8) (9) (10) (11) (12)

Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier Front bearing SPACER Pilot bearing Front oil seal Companion flange Self-locking nut

(16) (17) (18) (19) (20) (21) (22) (23) (24)

Side retainer Side oil seal Side gear thrust washer Side gear Pinion mate gear Spring pin Differential case Pinion mate shaft Air breather cap

(28) (29) (30)

Oil drain plug Rear cover Gasket

DI-6

Tightening torque:N·m (kgf-m, ft-lb) T1: 25 (2.5, 18.4) T2: 50 (5.1, 36.9) T3: 62 (6.3, 45.7) T4: 191 (19.5, 140.9)

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General Description DIFFERENTIALS

3. REAR DIFFERENTIAL (VA2-TYPE)

(1)

(19) (23)

(20)

(21) (22) (21)

(2)

(20)

(3)

(19)

(24)

(4) (5)

(17) (16) T4

(18)

(15) (14)

(26) (28) (25)

T1

(31)

(13)

T3 (30) (29)

(29) T2

(7) (27)

(6) (13) T1

(14)

(8)

(15) (16)

(9)

(17)

(10) T5 (12)

(11)

DI-00636

(1)

(14)

Side bearing

(27)

Rear cover

(2) (3)

Hypoid driven gear and drive pinion set Pinion height adjusting washer Rear bearing

(15) (16)

O-ring Side retainer

(28) (29)

Gasket Gasket

(4) (5) (6) (7)

Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier Front bearing

(17) (18) (19) (20)

Side oil seal Differential case Circlip Side gear thrust washer

(30) (31)

Oil filler plug Oil drain plug

(8) (9) (10) (11)

SPACER Pilot bearing Front oil seal Companion flange

(21) (22) (23) (24)

Side gear Pinion mate gear Spring pin Pinion mate shaft

(12) (13)

Self-locking nut Lock plate

(25) (26)

Air breather cap Stud bolt

DI-7

Tightening torque:N·m (kgf-m, ft-lb) T1: 25 (2.5, 18.4) T2: 34 (3.5, 25.1) T3: 50 (5.1, 36.9) T4: T5: 191 (19.5, 140.9)

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General Description DIFFERENTIALS

4. REAR DIFFERENTIAL MOUNTING SYSTEM

T2

(6)

(7)

(5) (6)

(3) (8)

(4)

(1) (7)

T3 (2) T1 T1

(7)

(7) DI-00619

(1) (2) (3) (4)

Mass damper (CVT model) Rear differential front member Rear differential member plate Rear differential ASSY

(5) (6) (7) (8)

Sub frame Rear differential mount bushing Self-locking nut Rear differential member plate (CVT model)

DI-8

Tightening torque:N·m (kgf-m, ft-lb) T1: 50 (5.1, 36.9) T2: 70 (7.1, 51.6) T3: 110 (11.2, 81.1)

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General Description DIFFERENTIALS

C: CAUTION • Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work. • Remove contamination including dirt and corrosion before removal, installation or disassembly. • Keep the disassembled parts in order and protect them from dust and dirt. • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. • Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts. • Use SUBARU genuine gear oil, grease or equivalent. Do not mix gear oil, grease, etc. of different grades or manufacturers. • Be sure to tighten fasteners including bolts and nuts to the specified torque. • Place shop jacks or rigid racks at the specified points. • Apply gear oil onto sliding or revolving surfaces before installation. • Before installing the O-ring or snap ring, apply a sufficient amount of gear oil to avoid damage and deformation. • Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise. • Avoid damaging the mating surface of the case.

DI-9

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General Description DIFFERENTIALS

D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION

TOOL NUMBER 398477701

DESCRIPTION HANDLE

REMARKS Used for installing the front and rear bearing cones.

398477702

DRIFT

• Used for press-fitting the bearing race of differential carrier (front). (T-type) • Used for press-fitting bearing race of differential carrier (rear). (VA1-type) • Used for press-fitting side bearing race. (VA1type)

398217700

ATTACHMENT SET

Stand for rear differential carrier disassembly and assembly.

498447120

INSTALLER

Used for installing the front oil seal.

ST-398477701

ST-398477702

ST-398217700

ST-498447120

DI-10

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 498427200

DESCRIPTION FLANGE WRENCH

REMARKS Used for stopping rotation of companion flange when removing and tightening self-lock nut.

398467700

DRIFT

• Used for removing pinion, pilot bearing and front bearing cone. • For T-type and VA1-type

399780104

WEIGHT

Used for installing the front bearing cone and the pilot bearing companion flange.

899580100

INSTALLER

Used for press-fitting the front bearing cone and pilot bearing.

899904100

STRAIGHT PIN REMOVER

Used for removing the spring pin of the differential pinion shaft.

ST-498427200

ST-398467700

ST-399780104

ST-899580100

ST-899904100

DI-11

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 498247001

DESCRIPTION MAGNET BASE

REMARKS • Used for measuring backlash between side gear and pinion, and hypoid gear. • Used together with DIAL GAUGE (498247100).

498247100

DIAL GAUGE

• Used for measuring backlash between side gear and pinion, and hypoid gear. • Used together with MAGNET BASE (498247001).

398507704

BLOCK

• Used for adjusting pinion height and preload. • For T-type and VA1-type

398177700

INSTALLER

• Used for installing the rear bearing cone. • For T-type and VA2-type

398457700

ATTACHMENT

• Used for removing the side bearing retainer. • For T-type

ST-498247001

ST-498247100

ST-398507704

ST-398177700

ST-398457700

DI-12

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 398477703

DESCRIPTION DRIFT 2

REMARKS • Used for press-fitting bearing race (rear) of differential carrier. • For T-type and VA2-type

398437700

DRIFT

• Used for installing the side oil seal. • For T-type and VA2-type

398507702

DUMMY SHAFT

• Used for adjusting pinion height and preload. • For T-type

398507703

DUMMY COLLAR

• Used for adjusting pinion height and preload. • For T-type

398517700

REPLACER

• Used for removing rear bearing cone. • For T-type and VA2-type

ST-398477703

ST-398437700

ST-398507702

ST-398507703

ST-398517700

DI-13

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 398487700

DESCRIPTION DRIFT

REMARKS • Used for press-fitting side bearing cone. • For T-type and VA2-type

398507701

DIFFERENTIAL CARRIER GAUGE

• Used for adjusting pinion height. • For T-type

398527700

PULLER ASSY

• Used for removing front oil seal. • Used for removing side bearing cup. (T-type)

398417700

DRIFT

• Used for installing side bearing race. • For T-type and VA2-type

ST-398487700

ST-398507701

ST-398527700

ST-398417700

28099PA090

OIL SEAL PROTEC- • Used for installing the rear drive shaft to the TOR rear differential. • For oil seal protection

ST28099PA090

DI-14

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 28099PA100

DESCRIPTION DRIVE SHAFT REMOVER

REMARKS • Used for removing the rear drive shaft from rear differential. • For T-type

399703600

PULLER ASSY

Used for removing companion flange.

899874100

INSTALLER

Used for installing the companion flange.

498077000

REMOVER

• Used for removing the differential side bearing cone. • For VA2-type

899864100

REMOVER

Used for removing the differential side bearing.

ST28099PA100

ST-399703600

ST-899874100

ST-498077000

ST-899864100

DI-15

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 499277200

DESCRIPTION INSTALLER

REMARKS • Used for installing the front bearing cone. • For VA2-type

18758AA000

PULLER

• Used for removing side bearing cup. • For VA2-type

18759AA000

PULLER ASSY

• Used for removing the differential side bearing cone. • For T-type

18678AA000

DUMMY SHAFT

• Used for adjusting pinion height and preload. • For VA2-type

18831AA010

DIFFERENTIAL CARRIER GAUGE

• Used for adjusting pinion height. • For VA2-type

ST-499277200

ST18758AA000

ST18759AA000

ST18678AA000

ST18831AA010

DI-16

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 18630AA010

DESCRIPTION WRENCH COMPL RETAINER

REMARKS • Used for removing and installing the side oil seal holder. • For VA-type • WRENCH ASSY (499787000) can also be used.

498175500

INSTALLER

• Used for installing the rear bearing cone. • For VA1-type

498447100

INSTALLER

• Used for installing the oil seal. • For VA1-type

399520105

SEAT

• Used for removing the side bearing cone. • Used together with PULLER SET (899524100). • For VA-type

899524100

PULLER SET

• Used for removing the differential side bearing cone. • For VA-type (1) Puller (2) Cap

ST18630AA010

ST-498175500

ST-498447100

ST-399520105

ST-899524100

DI-17

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 498485400

DESCRIPTION DRIFT

REMARKS • Used for installing side bearing cone. • For VA1-type

498505501

DIFFERENTIAL CARRIER GAUGE

• Used for adjusting pinion height. • For VA1-type

498447110

DRIFT

• Used for press-fitting the bearing race (front) of the differential carrier. • For VA1-type

498447150

DUMMY SHAFT

• Used for adjusting pinion height and preload. • For VA1-type

498515500

REPLACER

• Used for removing rear bearing cone. • For VA1-type

ST-498485400

ST-498505501

ST-498447110

ST-498447150

ST-498515500

DI-18

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 499705404

DESCRIPTION SEAT

REMARKS • Used for removing the side bearing race. • Used together with PULLER ASSY (499705401). • For VA1-type

499705401

PULLER ASSY

• Used for removing the side bearing race. • Used together with SEAT (499705404). • For VA-type

18270KA020

SOCKET (E20)

• Used for removing and installing the hypoid driven gear. • For VA2-type

18854AA000

ANGLE GAUGE

• Used for installing the hypoid driven gear. • For VA2-type

ST-499705404

ST-499705401

ST18270KA020

ST18854AA000

DI-19

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General Description DIFFERENTIALS ILLUSTRATION (6)

TOOL NUMBER 41399FG000

DESCRIPTION SPECIAL TOOL ASSY

41399FG010

SPECIAL TOOL A

41399FG020

SPECIAL TOOL B

• Used for installing the rear differential mount bushing. • For combination of tools for installation, refer to “SPECIAL TOOL ASSY (41399FG000)”.

41399FG030

SPECIAL TOOL C

• Used for removing the rear differential mount bushing. • For combination of tools for removal, refer to “SPECIAL TOOL ASSY (41399FG000)”.

(2) (5) (7) (4) (3) (8)

(1)

(9) ST41399FG000

REMARKS • Used for removing and installing the rear differential mount bushing. • Use (1), (3), (5), (6), (7), (8) and (9) for removal. • Use (2), (4), (5), (6), (7), (8) and (9) for installation. (1) SPECIAL TOOL A (41399FG010) (2) SPECIAL TOOL B (41399FG020) (3) SPECIAL TOOL C (41399FG030) (4) SPECIAL TOOL D (41399FG040) (5) SPECIAL TOOL SLEEVE (41399FG050) (6) SPECIAL TOOL RING (41399FG060) (7) SPECIAL TOOL NUT (41399FG070) (8) SPECIAL TOOL BEARING (41399FG080) (9) SPECIAL TOOL SHAFT (41399FG090) • Used for removing the rear differential mount bushing. • For combination of tools for removal, refer to “SPECIAL TOOL ASSY (41399FG000)”.

ST41399FG010

ST41399FG020

ST41399FG030

DI-20

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 41399FG040

DESCRIPTION SPECIAL TOOL D

REMARKS • Used for installing the rear differential mount bushing. • For combination of tools for installation, refer to “SPECIAL TOOL ASSY (41399FG000)”.

41399FG050

SPECIAL TOOL SLEEVE

• Used for removing and installing the rear differential mount bushing. • For combination of tools for removal and installation, refer to “SPECIAL TOOL ASSY (41399FG000)”.

41399FG060

SPECIAL TOOL RING

• Used for removing and installing the rear differential mount bushing. • For combination of tools for removal and installation, refer to “SPECIAL TOOL ASSY (41399FG000)”.

41399FG070

SPECIAL TOOL NUT

• Used for removing and installing the rear differential mount bushing. • For combination of tools for removal and installation, refer to “SPECIAL TOOL ASSY (41399FG000)”.

41399FG080

SPECIAL TOOL BEARING

• Used for removing and installing the rear differential mount bushing. • For combination of tools for removal and installation, refer to “SPECIAL TOOL ASSY (41399FG000)”.

ST41399FG040

ST41399FG050

ST41399FG060

ST41399FG070

ST41399FG080

DI-21

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General Description DIFFERENTIALS ILLUSTRATION

TOOL NUMBER 41399FG090

DESCRIPTION SPECIAL TOOL SHAFT

REMARKS • Used for removing and installing the rear differential mount bushing. • For combination of tools for removal and installation, refer to “SPECIAL TOOL ASSY (41399FG000)”.

41399YC000

SOCKET WRENCH (17)

Used for tightening the self-locking nut.

1B022XU0

SUBARU SELECT MONITOR III KIT

Used for troubleshooting the electrical system.

ST41399FG090

ST41399YC000

ST1B022XU0

2. GENERAL TOOL TOOL NAME Transmission jack Puller Thickness gauge Hexagon wrench Tire lever

REMARKS Used for removing and installing the rear differential. Used for removing the side bearing retainer. Used for measuring clearance. Used for installing and removing the oil filler plug and oil drain plug. Used for removing the rear drive shaft. (VA-type)

DI-22

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Differential Gear Oil DIFFERENTIALS

2. Differential Gear Oil

• VA2-type

A: INSPECTION 1) Remove the oil filler plug, and then check the gear oil. Replace the gear oil if it is contaminated or deteriorated. 2) Check that the gear oil level is within –5 mm (– 0.2 in) from the bottom of the oil filler plug hole. If the level is low, make sure that there is no oil leakage and refill up to the bottom of oil filler plug hole. NOTE: On VA1-types at factory settings, the oil level may be within –14 mm (–0.6 in) from the bottom of the oil filler plug. This is at normal level, requiring no oil refill. • T-type (A)

(B)

(A) (B)

DI-00355

(A) Oil filler plug (B) Oil drain plug

B: REPLACEMENT CAUTION: • Gear oil is extremely hot just after driving. Be wary of receiving burns. • If the differential gear oil is spilt over exhaust pipe, wipe it off with cloth to avoid emitting smoke or causing a fire. 1) Lift up the vehicle. 2) Remove the oil drain plug and oil filler plug, and drain the gear oil. • T-type

DI-00521 (A)

(A) Oil filler plug (B) Oil drain plug

(B)

• VA1-type (A)

DI-00356

(A) Oil filler plug (B) Oil drain plug (B)

• VA1-type DI-00574

(A) (B)

(A) Oil filler plug (B) Oil drain plug

DI-00575

(A) Oil filler plug (B) Oil drain plug

DI-23

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Differential Gear Oil DIFFERENTIALS

• VA1-type

• VA2-type

(A) (A)

(B)

(B) DI-00357

DI-00574

(A) Oil filler plug (B) Oil drain plug

(A) Oil filler plug (B) Oil drain plug

• VA2-type

3) Tighten the oil drain plug. NOTE: • For the T-type, apply liquid gasket to the oil drain plug.

Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent • For VA type, use a new gasket. (A)

Tightening torque: T-type 49 N·m (5.0 kgf-m, 36.1 ft-lb) VA-type: 50 N·m (5.1 kgf-m, 36.9 ft-lb) 4) Fill the differential carrier with gear oil to the bottom of oil filler plug hole.

5) Install the oil filler plug.

NOTE: Carefully refill oil while watching the level. Excessive or insufficient oil must be avoided.

NOTE: • For the T-type, apply liquid gasket to the oil filler plug.

Recommended gear oil:

Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent • For VA type, use a new gasket.

Oil capacity: 0.8 2 (0.8 US qt, 0.7 Imp qt) • T-type (B)

(B)

(A) Oil filler plug (B) Oil drain plug

Tightening torque: T-type: 49 N·m (5.0 kgf-m, 36.1 ft-lb) VA-type: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

(A)

DI-00355

DI-00391

(A) Oil filler plug (B) Oil drain plug

DI-24

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Front Differential Assembly DIFFERENTIALS

3. Front Differential Assembly A: NOTE 1. CVT MODEL For front differential for the CVT model, refer to the “CVT” section.

2. AT MODEL For front differential of 5AT model, refer to “5AT” section.

3. MT MODEL For front differential for the 6MT model, refer to the “6MT” section.

DI-25

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Rear Differential (T-type) DIFFERENTIALS

4. Rear Differential (T-type)

• For the VA-type, use the tire lever. T-type ST 28099PA100 DRIVE SHAFT REMOVER

A: REMOVAL 1) Set the vehicle on a lift. 2) Shift the select lever or gear shift lever to neutral. 3) Release the parking brake. 4) Disconnect the ground cable from battery. 5) Loosen the wheel nuts. 6) Lift up the vehicle. 7) Remove the rear wheels. 8) Drain differential gear oil. 9) Remove the rear exhaust pipe. • 2.5 L SOHC model

• 2.5 L DOHC turbo model

• 3.6 L model

10) Remove the heat shield cover.

ST

(A)

DI-00270

(A) BOLT

VA-type When removing the DOJ from the rear differential, place the tire lever against the bolt as shown in the figure so as not to damage the side retainer.

(A)

(B) DI-00287

(A) Tire lever (B) BOLT

DI-00620

11) Remove the propeller shaft. 12) Loosen the self-lock nuts which hold the rear differential to rear crossmember.

14) Set the rear differential to transmission jack.

DI-00633

DI-00621

13) Remove the DOJ of rear drive shaft from rear differential using ST or tire lever. NOTE: • For the T-type, use the ST.

DI-26

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Rear Differential (T-type) DIFFERENTIALS

15) Remove the mass damper. (CVT model)

• If a circlip is attached to the removed axle shaft for VA2 type, remove the differential case assembly and replace it with a new part.

DI-00622

16) Remove the rear differential front member.

DI-00624

21) Lower the transmission jack. 22) Secure the rear drive shaft to rear lateral link using wire.

DI-00358

17) Remove the self-locking nuts which hold the rear differential to the crossmember. 18) Remove the rear differential stud bolt from rear crossmember bushing. NOTE: When removing the stud bolt from the rear crossmember bushing, carefully adjust the angle and location of transmission jack and jack stand, if necessary.

DI-00625

23) Remove the rear differential member plate from rear differential. (B) (A)

DI-00626

(A) Rear differential member plate (CVT model) (B) Rear differential member plate

DI-00623

19) Lower the transmission jack. 20) Pull out the axle shaft from rear differential. NOTE: • If it is difficult to remove the axle shaft from rear differential, use the ST for T-type and the tire lever for VA-type. ST 28099PA100 DRIVE SHAFT REMOVER

DI-27

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Rear Differential (T-type) DIFFERENTIALS

B: INSTALLATION 1) Install the rear differential member plate to the rear differential.

6) Push the rear differential from side to side to insert the rear axle shaft into rear differential completely.

(B) (A)

DI-00627

DI-00626

7) Adjust the transmission jack, if necessary, and insert the rear differential stud bolt into rear crossmember bushing properly.

(A) Rear differential member plate (CVT model) (B) Rear differential member plate

2) Set the rear differential to transmission jack. 3) Set the ST to the rear differential. ST 28099PA090 OIL SEAL PROTECTOR

ST

DI-00623

8) After inserting the rear differential stud bolt into the rear crossmember bushing, lift up the transmission jack and align the rear differential to its attachment position.

DI-00279

4) Insert the rear axle shaft until the spline portion of the rear drive shaft exceeds the side oil seal.

DI-00628 DI-00280

9) Tighten a new self-locking nut temporarily to rear crossmember.

5) Remove ST from rear differential.

DI-00621

DI-28

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Rear Differential (T-type) DIFFERENTIALS

10) Install the rear differential front member with a new self-locking nut.

Tightening torque: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

Tightening torque: T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb) T2: 110 N·m (11.2 kgf-m, 81.1 ft-lb) T2

DI-00620

T1 DI-00629

11) Install the mass damper with a new self-locking nut. (CVT model)

Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft