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2002 IMPREZA SERVICE MANUAL QUICK

1. 23 5 5Ieering ditus ish arena 26 ME 55 47 55 8 Reservoir 70 9 JPowerSteenng F Ilo aciei 72 10 General Diagnostic 74 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING 1 General Description A SPECIFICATIONS Non TURBO Diners Sedan and TURBO OUTBACK Minimum turning radius m ft 5 1 16 7 5 4 17 7 2 system Steering wheel diameter mm in 385 15 16 Overall gear ratio Turns lock to lock 3 22 3 02 Gear box Whole 198108 angle Inside Outside 36 55 31 35 34 05 29935 _Rack and pinion Integral Gearbox Backlash 0 Automatically adjustable Valve Power steering system 3 Oil tank Installed on body Output cu in rev 7 8 0 476 7 2 0 439 1 7 164 7 840 7 350 8 036 75 82 jo kPa kgrcm psi 73 80 1 040 1 165 1 067 1 165 steering Hydraulic fluid control Dropping in response to increased engine revolutions system 1 000 rpm 7 7 4 6 2 7 5 7 9 6 6 Hydraulic fluid 0 US at Imp at 55 s d es d 2 Range of revolution rpm 700 9 000 Revolving direction ATF DEXRON
2. 2 ABS Control Module and Hydraulic Control Unit ABSCM amp MH U 7 ABS Sequence CON Ol oen rea ns tercer Us uis 11 ME 14 Hear ABS SelsOL aues tissue statu vato Mid cuted mirar 18 Front Tone URB cse oat nad saos dc aea ter rl er 21 Hear Tone Wheel usse dac 22 rcs necessaries tas ovine tints 23 GENERAL DESCRIPTION ABS 1 General Description A SPECIFICATIONS Em Rer 07 1 2 mm 0 028 0 047 in White wooo Yellow ABS sensor G sensor voltage 2 3 0 2 V ABS control module and hydraulic control unit ABSCM amp H U CC marks RH LH Marks of the h iius near LAH Light blue Brown AT ABS 2 GENERAL DESCRIPTION ABS B COMPONENT 1 SENSOR BRO0001 1 G sensor 4 Rear ABS sensor LH Tightening torque kgf m ft lb 2 Rear ABS sensor RH 5 Front ABS sensor LH T1 7 4 0 75 5 4 3 ABS spacer 6 Front ABS sensor RH T2 32 3 3 24 5 3 GENERAL DESCRIPTION ABS 2 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM amp H U 4 5 Py 2 1 G gt l Le 8 1 Stud bolt 6 Front RH outlet Tightening torque N m kgf m ft Ib 2 Damper 7 Primary inlet 71 18 1 8 13 0 3 ABS control module a
3. a Brake Pedal SIOB DIO gt 55 General DIAGNOSES a e ecu bandi san 57 GENERAL DESCRIPTION BRAKE 1 General Description A SPECIFICATIONS Non turbo Sedan and Turbo Other OUTBACK 15 inch 16 Disc Floating type ventilated 228 mm 8 98 in 247 mm 9 72 in 24 x 277 mm 24 x 294 mm 0 94 x 10 91 in 0 94 x 11 57 in 42 8 mm 1 685 in x 2 105 0 x 50 5 x 11 0 mm 112 3 x 50 0x 11 0 mm 4 184 x 1 989 x 0 433 in 4 421 x 1 969 x 0 433 in Automatic adjustment Size Type Effective disc diameter Disc thickness x Outer diameter Front disc brake Effective cylinder diameter Pad dimensions length x width x thickness Clearance adjustment Type Disc Floating type Effective disc diameter 230 mm 9 06 in 10 x 266 mm Disc thickness x Outer diameter 0 39 10 47 Rear disc brake Effective cylinder diameter 38 1 mm 1 500 in Pad dimensions 82 4 x 33 7 x 9 0 mm length x width x thickness 3 244 x 1 327 x 0 354 in Clearance adjustment he Automatic adjustment Leading Trailing type Effective drum diameter 228 6 mm 9 Effective cylinder diameter 19 0 mm 0 689 in Rear drum brake Lining dimensions 219 3 x 35 0 x 4 1 mm length x width x thickness 8 63 x 1 378 x 0 161 in Clearance a
4. 2 24 8 Font CrossSmembOen 25 9 General Diagnostic vec 26 GENERAL DESCRIPTION FRONT SUSPENSION 1 General Description A SPECIFICATIONS 1 STABILIZER Moi Bardameer ALL MODEL 20 mm 0 79 in 2 WHEEL ALIGNMENT Sedan e Sedan Turbo E Camber iolerance 30748 Caster common difference 50 45 Toe in 0 3 mm 0 0 12 in Each toe angle 0 07 30 Total toe angle 0 15 Wheel arch height 396 mm 406 mm 387 mm 397 mm tolerance 12 mm 0 47 in 15 59 in 15 98 in 15 24 in 15 63 in 15 83 in NOTE e Front and rear toe ins and front camber be adjusted If the toe in or camber tolerance exceeds specifications adjust toe in and camber to the mid dle value of specification he other items indicated in the specification ta ble cannot be adjusted If the other items exceeds specifications check suspension parts and nections for deformities replace with new ones as required 4 2250 1 Front Positive Toe in Negative Toe out a Each toe angle FS 2 GENERAL DESCRIPTION FRONT SUSPENSION FS 3 GENERAL DESCRIPTION FRONT SUSPENSION B COMPONENT FS 4 GENERAL DESCRIPTION FRONT SUSPENSION 1
5. CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary poor contact CHECK OPEN CIRCUIT SENSOR OUT 15 the resistance between 4 3 PUT HARNESS AND GROUND HARNESS 4 9 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Measure the resistance between ABSCM amp H U connector terminals Connector amp terminal F49 No 6 No 28 CHECK G SENSOR 1 Remove the console box 2 Remove the G sensor from vehicle 3 Connect the connector to G sensor 4 Connect the connector to ABSCM amp H U 5 Turn the ignition switch to ON 6 Measure the voltage between G sensor con nector terminals Connector amp terminal B292 No 2 No 3 Repair harness connector between G sensor and ABSCM amp H U Replace the G sensor Ref to ABS 23 G Sen sor gt Is the voltage between 2 1 and 2 5 V when G sensor is hori zontal ABS 181 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK G SENSOR Is the voltage between 3 7 and Go to step 11 Replace the G Measure the voltage between G sensor con 4 1 V when sensor is sensor Ref to nector terminals inclined forwards to 90 ABS 23 G Sen Connector amp terminal Sor B292 No 2 No 3 CHECK G SENSOR Is the voltage between 0 5 and Go to
6. CHECK UNIVERSAL JOINT Measure the folding torque of the joint yoke of steering column side Ref to PS 22 INSPECTION Universal Joint CHECK UNIVERSAL JOINT Measure the folding torque of the joint yoke of gearbox side Ref to PS 22 INSPECTION Universal Joint Is the folding torque 7 3 N 0 74 kgf 1 64 Ib or less Is the folding torque 7 3 N 0 74 kgf 1 64 Ib or less CHECK FRONT WHEEL Are the front wheels for Inspect readjust to step 8 unsteady revolution or rattling jand replace if nec and brake for dragging essary CHECK TIE ROD ENDS Are the tie rod ends of suspen Inspect and Go to step 9 Remove the tie rod ends replace if neces sary Inspect and replace if neces sary Go to step 11 sion for unsteady revolution or ratting Are the ball joints of suspen sion for unsteady revolution or ratting Is rotating resistance 12 7 1 3 kgf 2 9 Ib or less in all positions within 20 difference between clockwise and coun terclockwise Is sliding resistance 340 35 kgf 76 Ib or less with 20 dif ference between left and right direction CHECK BALL JOINT Go to step 10 CHECK GEARBOX Measure the rotating of gearbox lt Ref to PS 44 TURNING RESISTANCE OF GEARBOX INSPECTION Steering Gear box gt CHECK GEARBOX Measure sliding of gearbox lt Ref to PS 43 SERVICE LIMIT
7. SWITCH DATA LINK CONNECTOR RELAY HOLDER B40 B40 B200 16 17 18 19 9 20 21 22 ae ee 8 1 2 314 5 61 7 8 i 6 0091 5 96 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS seid Gk Yes 1 CHECK IGNITION SWITCH Is the ignition switch ON Go to step 2 Turn the ignition switch to ON and select ABS mode using the select monitor Charge or replace bettery Repair or tighten Go to step 4 the battery termi nal Go to step 10 Go to step 5 Go to step 10 Go to step 6 Inspect the ECM Go to step 7 Go to step 8 CHECK BATTERY 1 Turn the ignition switch to OFF 2 Measure the battery voltage CHECK BATTERY TERMINAL Is the voltage more than 11 V Go to step 3 Is there poor contact at battery terminal CHECK COMMUNICATION OF SELECT MONITOR 1 Turn the ignition switch to OFF 2 Using the select monitor check whether communication to other system such as engine TCM etc can be executed normally CHECK COMMUNICATION OF SELECT MONITOR 1 Turn the ignition switch to OFF Disconnect the ABSCM amp H U connector 3 Check whether communication to other sys tems such as TCM engine etc can be exe cuted normally CHECK COMMUNICATION OF SELECT MONITOR 1 Turn the ignition switch to OFF 2
8. Working fluid 0 3 0 3 0 3 Power Capacity steering 0 US qt Imp qt Total 0 7 0 7 0 6 system 1 With maximum load 2 With no load PS 2 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING 7 0 67 inner tire amp TURBO OUTBACK Non TURBO sedan 34 05 1 5 wheel Turning angle 3 mm Steering wheel Free play other 36 55 1 5 Outer tire amp TURBO OUTBACK Non TURBO sedan 29 35 1 5 wheel EE 0 1 1 Steering shaft Clearance between steering wheel and mm in 3 0 0 118 column cover Sliding resistance N kgf b 340 35 76 or less Right turn steering mm in 0 19 0 0075 or less Steering gear nace Horizontal movement play in radial 0 15 0 0059 less box direction Left turn steering mm in Variceal moveant Power steer 0 3 0 012 or less ing system Input shaft in radial direction mm 0 18 0 0071 or less play In axial direction mm in 0 5 0 020 or less Maximum allowable value 12 1 2 2 7 Radial play mm in 0 4 0 016 or less Pulley shaft Non TURBO mm in 0 4 0 016 or less Axial play TURBO mm in 0 8 0 031 or less Turning resistance kgf Ib Ditch deflection mm in 1 0 0 039 or less Pulley Oil pump Power steer Resistance to rotation kgf Ib 9 22 0 94 2 07 or less ing system Regular pressu
9. Tightening torque Large boot band 157 16 0 kgf m 116 ft lb or more Small boot band 133 N m 13 6 kgf m 98 or more 9 Place the SFJ boot at the center of shaft 10 Align alignment marks and install the trunnion on the shaft 11 Install the snap ring to the shaft CAUTION Confirm that the snap ring is completely fitted in the shaft groove 12 Fill 100 to 110 g 3 53 to 3 88 oz of specified grease into the interior of SFJ outer race 13 Apply a coat of specified grease to the free ring and trunnion 14 Align alignment marks on free ring and trunnion and install the free ring CAUTION Be careful with the free ring position 4 0777 15 Align alignment marks on shaft and outer race and install outer race 16 Instail the circlip in the groove on the SFJ outer race CAUTION Pull the shaft lightly and assure that the circlip is completely fitted in the groove 17 Apply an even coat of the specified grease 30 to 40 g 1 06 to 1 41 oz to the entire inner surface of boot 18 Install the SFJ boot taking care not to twist it CAUTION e The inside of the larger end of SFJ boot and the boot groove shall be cleaned so as to be free from grease and other substances e When installing SFJ boot position outer race of SFJ at center of its travel DS 36 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM 19 Put a band through the clip and wind twice in alignment with band groove
10. or less 3 Turn the ignition switch OFF 4 Within 0 5 seconds after the ABS warning light goes out depress the brake pedal and hold it im mediately after the ignition switch is turned to ON CAUTION Do not depress the clutch pedal NOTE When the ignition switch is set to on the brake pedal must not be depressed Engine must not operate 5 After completion of ABS sequence control turn the ignition switch OFF 2 ABS SEQUENCE CONTROL WITH SE LECT MONITOR NOTE n the event of any trouble the sequence control may not be operative In such a case activate the sequence control referring to ABS SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR Ref to ABS 11 ABS SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR ABS Sequence Control When the diagnosis terminal is connected to the diagnosis connector the sequence control will not operate 1 Connect the select monitor to data link connector under the driver s seat instrument panel lower cov er 2 Turn the ignition switch ON 3 Turn the select monitor switch ON 4 Put the select monitor to BRAKE CONTROL mode 5 When Function check sequence is selected ABS sequence control will start 6 The message Press Brake Pedal Firmly is dis played as follows 1 When using the brake tester depress the brake pedal with braking force of 981 N 100 kgf 221 Ib 2 When using the pressure gauge depress the brake pedal so as to make the pressure
11. 11 5 kgf m 83 ft Ib DS 27 REAR AXLE DRIVE SHAFT SYSTEM 5 Connect the rear stabilizer to the rear lateral link CAUTION Use a new self locking nut Tightening torque 44 4 5 kgf m 32 5 ft lb 6 Connect the parking brake cable to the parking brake 7 Clean the brake pipe connection Using a flare nut wrench connect the brake pipe to the wheel cylinder 8 Connect the rear ABS sensor to the back plate only vehicle equipped with ABS H4M1139B 1 ABS sensor 9 Connect the parking brake cable to the lever 10 Install the brake drum on the rear housing as sembly 11 Bleed air from brake system lt Ref to BR 44 REPLACEMENT Brake Fluid gt 12 Adjust the parking brake lever stroke by turning adjuster 13 Move the brake lever back to apply brakes While depressing brake pedal tighten the axle nut using a socket wrench Lock the axle nut after tight ening Tightening torque 186 N m 19 kgf m 137 ft lb CAUTION e Use a new axle nut Always tighten axle nut before installing wheel on vehicle If wheel is installed and comes in contact with ground when axle nut is loose wheel bearings may be damaged Be sure to tighten axle nut to specified torque Do not overtighten it as this may dam age wheel bearing 14 Install the wheel and tighten the wheel nuts to specified torque Tightening torque 90 N m 9 2 kgf m 66 5 ft lb C DISASSEMBLY 1 Using ST1 an
12. 3 Scored or chipped teeth of hypoid Replace hypoid gear set mission propeller shaft wheel bearings tires and body are sometimes mistaken for noises from differential assembly be Seized hypoid gear Replace hypoid gear set careful in checking them Inspection 5 Improper preload for front or rear Readjust methods to locate noises include coast bearings ing accelerating cruising and jacking up 6 Seized scored or chipped front or Replace all four wheels Perform these inspections rear bearing according to condition of trouble When 7 Seized scored or chipped side bear Replace listening to noises shift gears into four ing wheel drive and fourth speed position O 8 Vibrating differential carrier Replace ing to pick up only differential noise DI 42 TRANSFER CASE OO OO eS General 2 Transfer Case and Extension for MT menn 3 Transfer Clutch and Extension for AT 4 Transter Drive Gear WE RR UA Transter Dnver Gear Reduction Drive Gear without VTD Reduction Drive Gear with Reduction Driven Gear without VTD 10 Reduction Driven Gear with 44 440 11 Conter
13. For non turbo model H4M1408 PS 16 REMOVER OIL SEAL Used for removing back up ring and oil seal GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING ILLUSTRATION TOOL NUMBER DESCRIPTION 34099AC040 INSTALLER B Used for installing retaining ring Used with INSTALLER 34099 030 e For non turbo model H4M1409 PS 17 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING 2 GENERAL PURPOSE TOOLS PS 18 STEERING WHEEL 2 Steering Wheel A REMOVAL 1 Disconnect the ground terminal from battery 2 Set the tires to straight ahead position 3 Remove the airbag module lt Ref to AB 12 RE MOVAL Driver s Airbag Module WARNING Always refer to Air Bag System before per forming airbag module service Ref to AB 12 CAUTION Driver s Airbag Module 4 Remove the steering wheel nut and then draw out the steering wheel from the shaft using steering puller NOTE Make the matching marks on the steering wheel and steering column in advance 1 Matching mark POWER ASSISTED SYSTEM POWER STEERING B INSTALLATION 1 Align the center of roll connector Ref to AB 17 ADJUSTMENT Roll Connector 2 Install in the reverse order of removal NOTE Align the matching marks on the steering wheel and steering column Tightening torque 44 N m 4 5 kgf m 32 5 Column cover to steering wheel clearance
14. 0054 1 Parking brake lever 2 Lock nut 3 Adjusting nut 6 Remove the brake drum from hub 7 If it is difficult to remove brake drum remove the adjusting hole cover from the back plate and then turn the adjusting screw using a slot type screw driver until the brake shoe separates from the drum 1 Back plate 2 Wheel cylinder 3 Adjuster ASSY pawls 4 Adjusting lever 5 Tightening direction 6 Push DS 24 REAR AXLE DRIVE SHAFT SYSTEM NOTE If brake drum is difficult to remove drive it out by in stalling an 8 mm bolt into bolt hole in brake drum 8 Using a flare net wrench disconnect the brake hose from the wheel cylinder CAUTION Cover open end of wheel cylinder to prevent en try of foreign particles 54 0368 1 Cable end 10 Disconnect the rear stabilizer from the rear lat eral link 11 Remove the bolts which secure trailing link as sembly to the rear housing CAUTION Discard old self locking nut Replace with a new one 12 Remove the bolts which secure lateral link as sembly to the rear housing CAUTION Discard old self locking nut Replace with a new one 13 Disengage the BJ from the housing splines and remove the rear drive shaft assembly If it is hard to remove use STs ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXLE SHAFT PULLER PLATE CAUTION Becareful not to damage the oil seal lip when removing rear drive s
15. 5 Chassis ground 2 CHECK RELAY HOLDER Is the fuse blown out Replace the fuse to step 3 3 CHECK INPUT VOLTAGE OF ABS RELAY 115 the voltage more than 10 V So to step 4 Repair open circuit the fuse iin harness 2 Remove the ABS relay between battery 3 Turn the ignition switch to ON and Relay holder 4 Measure the voltage between ABS relay connector connector and chassis ground Connector amp terminal B264 No 2 Chassis ground 1 CHECK INPUT VOLTAGE OF ABS RELAY Measure the voltage between ABS relay con nector and chassis ground Connector amp terminal B264 No 1 Chassis ground CHECK GROUND CIRCUIT OF ABS RELAY 1 Turn the ignition switch to OFF 2 Measure the resistance between ABS relay connector and chassis ground Connector amp terminal B264 No 3 Chassis ground CHECK ABS RELAY 1 Connect the battery to ABS relay terminal No 1 and 3 2 Measure the resistance between ABS relay terminals CHECK INPUT VOLTAGE OF ABSCM amp H U 1 Turn the ignition switch to OFF 2 Disconnect the connector ABSCM amp H U 3 Run the engine at idle 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 1 Chassis ground F49 No 24 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U 8 Is resistance less than 0 5 Go to step 9 Repair the 1 Turn the ignition switch to OFF
16. CHECK DAMAGE OF ABS SENSOR OR TONE WHEEL Are there broken or damaged teeth in the ABS sensor piece or the tone wheel CHECK TONE WHEEL RUNOUT Measure the tone wheel runout Replace the tone wheel Front lt Ref to ABS 21 Front Tone Is the runout less than 0 05 mm 0 0020 in Wheel gt Rear lt Ref to ABS 22 Rear Tone Wheel gt Go to step 13 CHECK ABSCM amp H U 1 Turn the ignition switch to OFF 2 Connect ail connectors 3 Erase the memory 4 Perform the inspection mode 5 Read out the diagnostic trouble code Is the same diagnostic trouble code as in the current diagno sis still being output Replace the ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Proceed with the diagnosis corre sponding to the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE A temporary poor contact Are other diagnostic trouble codes being output ABS 56 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS M DTC 31 ABNORMAL INLET SOLENOID VALVE CIRCUIT S INABSCM amp H U FRONT RH NOTE For the diagnostic procedure refer to DTC 37 lt Ref to ABS 57 DTC 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR LH Diagnostics Chart with Diagnosis Connector N DTC 33 ABNORMAL INLET SOLENOID VALVE
17. Chassis ground CHECK DIAGNOSIS LINE 1 Turn the ignition switch to OFF 2 Connect the diagnosis terminal B81 to diagnosis connector B82 No 6 3 Disconnect the connector from ABSCM amp H U 4 Measure the resistance between 5 connector and chassis ground Connector amp terminal F49 No 4 Chassis ground CHECK GENERATOR 1 Start the engine 2 ldle the engine 3 Measure the voltage between generator and chassis ground Terminal Generator B terminal 4 Chassis ground 5 CHECK BATTERY TERMINAL Is there poor contact at battery Repair the battery to step 6 Turn the ignition switch to OFF terminal terminal CHECK POWER SUPPLY OF ABSCM Is the voltage between 10 and Go to step 7 Repair the 15 V ABSCM amp H U power supply cir cuit 1 Disconnect the connector from ABSCM amp Does the ABS warning light Go to step 8 Repair the front H U remain off wiring harness Repair harness connector between ABSCM amp H U and diagnosis connec tor Is the resistance less than 0 5 2 Go to step 4 Go to step 5 Go to step 3 Repair the genera tor Ref to SC 13 Generator Is the voltage between 10 and 15 V 2 Start the engine 3 ldle the engine 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 1 Chassis ground CHE
18. SENSOR 5 8 G Sensor B INSTALLATION 1 Install in the reverse order of removal A REMOVAL 1 Disconnect the ground terminal from batte CAUTION 9 Do not drop or bump the sensor Tightening torque G sensor 32 3 3 kgf m 24 ft lb 2 Remove the console cover lt Ref to El 41 Console Box gt 3 Disconnect the connector from G sensor 4 Remove the G sensor from body CAUTION Do not drop or bump the G sensor ABS 23 SENSOR 5 INSPECTION CHECK SUBARU SELECT MONITOR CHECK G SENSOR 1 Turn the ignition switch to OFF 2 Remove the G sensor from vehicle 3 Connect the connector to G sensor 4 Turn the ignition switch to ON 5 Measure the voltage between G sensor con nector terminals Connector amp terminal B292 2 No 3 CHECK G SENSOR Measure the voltage between G sensor con nector terminals Connector amp terminal B292 No 2 3 CHECK G SENSOR Measure the voltage between G sensor con nector terminals Connector amp terminal B292 No 2 3 CHECK G SENSOR 1 Turn the ignition switch to OFF 2 Connect the select monitor connector to data link connector 3 Turn the select monitor into BRAKE CON TROL mode 4 Set the display in the Current Data Display amp Save mode 5 Read the G sensor output voltage CHECK G SENSOR 1 Remove the console box 2 Remove the G sensor from vehicl
19. TRANSFER CLUTCH PRESSURE TEST TRANSFER CASE 12 Transfer Clutch Pressure Test A NOTE For inspection work refer to AT section lt Ref to AT 18 Transfer Clutch Pressure Test gt TC 13 TRANSFER DUTY SOLENOID AND VALVE BODY TRANSFER CASE 13 Transfer Duty Solenoid and Valve Body A NOTE For removal installation and inspection work refer to AUTOMATIC TRANSMISSION a separate publication Pub No GO853ZE or AT section lt Ref to AT 39 Shift Solenoids Duty Solenoids and ATF Temperature Sensor gt TC 14 DRIVE SHAFT SYSTEM SLM 2 2 DR ROAR ANIC ost Ec uM UO edo MEE 5 Front Drive Shaft aia 6 Front Drive Shaft 7 ee cea 8 RBRearbDnve Shat BOOS NEQNE 9 General Diagnostic Table GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 1 General Description A SPECIFICATIONS 1 PROPELLER SHAFT Propeller shaft type DOJ type UJ type Front propeller shaft Joint to joint length L4 mm in GST gt VES Rear propeller shaft Joint to joint length Lo mm in 713 28 07 708 27 87 D 63 5 2 500 Outside diameter of tube mm in 57 0 2 244 Traum A UJtype B DOJ type 0 0008 DS 2 GEN
20. s the G sensor output on mon tor display more than 3 65 V s the resistance between 4 3 ind 4 9 Repair harness between G senso ABSCM amp H U s the voltage less than 1 V 3o to step 12 ABS 171 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS SS CHECK BATTERY SHORT OF HARNESS Is the voltage less than 1 V Go to step 13 Repair harness 1 Turn the ignition switch to ON 2 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal 49 No 6 Chassis ground between G sensor and ABSCM amp H U CHECK POOR CONTACT IN CONNECTORS 15 there poor contact in con Repair the con Go to step 14 nector between ABSCM amp H U and G sensor CHECK ABSCM amp H U Is the same diagnostic trouble Replace the 1 Connect all connectors code as in the current diagno ABSCM amp H U 2 Erase the memory sis still being output _ Ref to ABS 7 3 Perform the inspection mode ABS Control Mod 4 Read out the diagnostic trouble code ule and Hydraulic Control Unit ABSCM amp H U Proceed with the diagnosis corre sponding to the diagnostic trouble Go to step 15 Are other diagnostic trouble codes being output CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE A temporary poor contact code
21. 3 CHECK INPUT VOLTAGE OF ABS RELAY 5 the voltage more than 10 V Repair open circuit 1 Install the fuse in harness 2 Remove the ABS relay between battery Go to step 5 in harness between battery and Relay holder connector 3 Turn the ignition switch to ON and Relay holder 4 Measure the voltage between ABS relay connector connector and chassis ground Connector amp terminal B264 2 Chassis ground CHECK INPUT VOLTAGE OF ABS RELAY Measure the voltage between ABS relay con nector and chassis ground Connector amp terminal B264 No 1 4 Chassis ground CHECK GROUND CIRCUIT OF ABS RELAY 1 Turn the ignition switch to OFF 2 Measure the resistance between ABS relay connector and chassis ground Connector amp terminal B264 No 3 Chassis ground Repair harness connector between battery ignition switch and ABS relay Repair open circuit between ABS relay and chassis ground Is the voltage more than 10 V Is the resistance less than 5 2 CHECK the ABS RELAY Is the resistance less than 10 Go to step 7 Replace the ABS 1 Connect the battery to ABS relay terminal 0 relay No 1 and 3 2 Measure the resistance between ABS relay terminals CHECK INPUT VOLTAGE OF ABSCM amp H U 1 Disconnect the connector from ABSCM amp H U 2 Run the engine at idle 3 Measure the voltage between A
22. 5 152 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Pte eek Ye 1 CHECK INPUT VOLTAGE OF ABSCM amp H U 15 the voltage between 10 and Go to step 2 Repair harness 13 connector between battery and ABSCM amp H U and check fuse SBF6 Go to step 3 Repair the ABSCM amp H U ground harness Go to step 4 Replace the ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Turn the ignition switch to ON 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 25 Chassis ground CHECK GROUND CIRCUIT OF MOTOR 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 26 Chassis ground CHECK MOTOR OPERATION Operate the sequence control Ref to ABS 11 ABS Sequence Control NOTE Use the diagnosis connector to operate the se quence control s the resistance less than 0 5 Can the motor revolution noise buzz be heard when carrying out the check sequence CHECK POOR CONTACT IN CONNECTORS 5 there poor contact con Repair the con Go to step 5 Turn the ignition switch to OFF nector between hydr
23. ABS 23 LIST OF DIAGNOSTICS TROUBLE CODE DTC ABS DIAGNOSTICS 11 List of Diagnostics Trouble Code DTC A LIST 1 WITHOUT SUBARU SELECT MONITOR DTC No Contents of diagnosis Start code DTC is shown after start code Only start code is shown in normal condition m Front right ABS sensor 2 Front lef S S Abnormal ABS sensor oltage too high id igh Rear right ABS sensor Rear left ABS sensor Front right inlet valve Front right outlet valve Front left inlet valve 34 Abnormal solenoid Front left outlet valve valve circuit s ABS control module and 35 hydraulic unit Rear right inlet valve Rear right outlet valve Rear left inlet valve Rear left outlet valve lt Ref to ABS 40 DTC 21 ABNORMAL ABS SENSOR OPEN CIR CUIT OR INPUT VOLTAGE HIGH FRONT Diagnostics Chart with Diagnosis Connector Ref to ABS 40 DTC 23 ABNORMAL ABS SENSOR OPEN CIR CUIT OR INPUT VOLTAGE TOO HIGH FRONT LH Diagnostics Chart with Diagnosis Connector Ret to ABS 40 25 ABNORMAL ABS SENSOR OPEN CIR CUIT OR INPUT VOLTAGE TOO HIGH REAR RH Diagnostics Chart with Diagnosis Connector Ref to ABS 41 DTC 27 ABNORMAL ABS SENSOR OPEN CIR CUIT OR INPUT VOLTAGE TOO HIGH REAR LH Diagnostics Chart with Diagnosis Connector Ref to 5 46 DTC 22 ABNORMAL ABS SENSOR FRONT RH Front right ABS se
24. Keep the disassembled parts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement e careful not to burn your hands because each part in the vehicle is hot after running e Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or safety stands at the specified points Apply grease onto sliding or revolution surfaces before installation Before installing O rings or snap rings apply suf ficient amount of grease to avoid damage and de formation Before securing part on vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice Do not put fluid on body If the body is tainted wash away with water BR 14 5 i E 5 d GENERAL DESCRIPTION BRAKE D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 926460000 WHEEL CYLINDER Used for installing cup onto wheel cylinder piston 4 2406 3 4 ADAPTER Size 11 16 in 2 GENERAL PURPOSE TOOLS TOOL NAME REMARKS SNAP RING PLIERS Used for removing and installing snap ring BR 15 FRONT BRAKE PAD
25. PS 73 POWER ASSISTED SYSTEM POWER STEERING GENERAL DIAGNOSTIC TABLE POWER ASSISTED SYSTEM POWER STEERING 10 General Diagnostic Table A INSPECTION Trouble Possible cause Corrective action Pulley belt Unequal length of pulley belts Adhesion of oil and grease Loose or damage of pulley belt Poor uniformity of pulley belt cross section Pulley belt touches to pulley bottom Poor revolution of pulleys except oil pump pulley Poor revolution of oil pump pulley Tire and rim Improper tires out of specification Improper rims out of specification Tires not properly inflated 1 Fluid e e i Adjust or replace Replace or reinflate Heavy steering effort in all ranges Heavy steering effort at ew stand still Low fluid level Steering wheel surges when Aeration Refill bleed air replace or turning Dust mix instruct customer Deterioration of fluid Poor warming up of fluid 2 Idling speed Lower idling speed Excessive drop of idling speed at start or at turning steering wheel 3 5 Measure hydraulic pressure lt Ref to PS 66 INSPECTION Replace problem parts Oil Pump gt 6 Measure steering effort lt Ref to PS 74 INSPECTION Gen Adjust or replace eral Diagnostic Table gt 1 Fluid line e Folded hose Flattened pipe Tire and rim Flat tire Mix use of different tires Mix use of different rims Abno
26. START On after starting Engine is running On after starting Engine is stop Timing Immediately after ignition is ON immediately after ignition starts When advancing km h to km h MPH to MPH LJ While traveling at a constant speed L When decelerating km h to km h MPH to MPH When turning to right I When turning to ef Steingange 99 e Parts name e Operating condition ABS 6 CHECK LIST FOR INTERVIEW ABS DIAGNOSTICS 2 SYMPTOMS ABS operating condi Performs no work tion Operates only when abruptly applying brakes Vehicle speed How to step on brake pedal e What kind of noise Knock Gong gong Bong Buzz Gong gong buzz Others c Reaction force of brake pedal 2 Stick Press down once with clunk Press and released Others a Directional stability cannot be obtained or steering arm refuses to work when applying brakes Yes No e When LJ Vehicle turns to right Vehicle turns to left Spins Others b Directional stability cannot be obtained or steering arm refuses to work when accelerating Q Yes No e When Vehicle turns to right Q Vehicle turns to left Q Spins Others C Brakes are out of order Yes No e What Q Braking distance is long Brakes lock or drag J Pedal stroke is long Pedal sticks Others d Poor
27. 3 Damage 1 Improper backlash for hypoid gear NOTE 2 Insufficient or excessive preload for Readjust or replace Damaged parts should be replaced and side rear or front bearing also other parts should be thoroughly checked for any defect and should be backlash for differential Replace gear or thrust washer paired or replaced as required 4 Loose bolts and nuts such as crown Retighten gear bolt 5 Damage due to overloading 4 Noises when starting or shifting 1 Excessive backlash for hypoid gear gears 2 Excessive backlash for differential Replace gear or thrust washer NOTE gear 01565 Be 15 differential as 3 Insufficient preload for front or rear Readjust sembly universal joint wheel bearing bearn etc Find out what is actually making noise 9 before disassembly 4 Loose drive pinion nut Tighten to specified torque 5 Loose bolts and nuts such as side Tighten to specified torque bearing retainer attaching bolt 5 Noises when cornering 1 Damaged differential gear 2 Excessive wear or damage of thrust Replace washer 3 Broken pinion mate shaft 4 Seized or damaged side bearing DI 41 GENERAL DIAGNOSTIC TABLE DIFFERENTIALS Symptom or rouble 6 Gear noises 1 Improper tooth contact of hypoid gear Readjust or replace hypoid gear set 2 Improper backlash for hypoid gear Readjust
28. ABSCM amp H U 2 Measure the resistance between ground harness ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 23 Chassis ground CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con Repair the con nectors between generator nector battery and ABSCM amp H U Repair harness connector between battery ignition switch and ABS relay Repair open circuit between ABS relay and chassis ground Is the voltage more than 10 V Go to step 5 Is the resistance less than 5 2 Go to step 6 Replace the ABS relay 5 the resistance less than 10 Q Go to step 7 Repair harness connector between battery and ABSCM amp H U Is the voltage between 10 and Go to step 8 Go to step 10 10 CHECK ABSCM amp H U Is the same diagnostic trouble Replace the Go to step 11 1 Connect all connectors code as in the current diagno ABSCM amp H U 2 Erase the memory sis still being output lt Ref to ABS 7 3 Perform the inspection mode ABS Control Mod 4 Read out the diagnostic trouble code ule and Hydraulic Control Unit ABSCM amp H U gt ABS 145 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK ANY OTHER DIAGNOSTIC TROU other diagnostic trouble Proceed with the temporary poor BLE CODES APPEARANCE codes being output diagnosis
29. Crown gear to drive pinion backlash Crown gear runout on its back sunface Part No 383705200 383715200 383725200 383735200 383745200 383755200 383765200 383775200 383785200 383795200 383805200 383815200 383825200 383835200 383845200 Part No 383495200 383505200 383515200 383525200 Length 2 59 mm 0 1020 in 2 57 mm 0 1012 in 2 55 mm 0 1004 in 2 53 mm 0 0996 in 2 51 mm 0 0988 in 2 49 mm 0 0980 in 2 47 mm 0 0972 in 2 45 mm 0 0965 in 2 43 mm 0 0957 in 2 41 mm 0 0949 in 2 39 mm 0 0941 in 2 37 mm 0 0933 in 2 35 mm 0 0925 in 2 33 mm 0 0917 in 2 31 mm 0 0909 in Thickness 3 09 mm 0 1217 in 3 12 mm 0 1228 in 3 15 mm 0 1240 in 3 18 mm 0 1252 in 3 27 mm 0 1287 in 333 mm 0 1311 in 3 39 mm 0 1385 in 3 42 mm 0 1346 in 348 mm 0 1370 in 3 54 mm 0 1394 in 3 57 mm 0 1406 in 3 63 mm 0 1429 in 3 66 mm 0 1441 in 0 1 0 2 mm 0 0039 0 0079 in 0 80 0 85 mm 0 0315 0 0335 in 20 00 ren 0 7874 iN 0 20 mm 0 0079 in 040 mm 0 0157 in 0 10 0 20 mm 0 0039 0 0079 in 0 05 mm 0 0020 in DI 3 GENERAL DESCRIPTION DIFFERENTIALS B COMPONENT 1 REAR DIFFERENTIAL WITHOUT LSD 1 2 3 4 2 Kig se 4 5 ue Pinion crown gear set Pinion height adjusting washer Rear bearing Bearing preload adjusting spacer 1 48 19 21 20 A E eT a E 20 Side bearing O rin
30. Is the gap within the specifica tions 0 3 0 8 mm 0 012 0 031 in Rear wheel 0 7 1 2 mm 0 028 0 047 in 3 Connect the oscilloscope to the connector 4 Turn the ignition switch ON 5 Rotate the wheels and measure voltage at specified frequency Ref to ABS 17 WAVE FORM Control Module 1 Signal NOTE When this inspection is completed the ABS control module sometimes stores the DTC 29 Connector amp terminal DTC 22 F95 No 1 No 2 DTC 24 F94 No 1 No 2 DTC 26 B99 9 No 10 DTC 28 B99 No 4 5 CHECK CONTAMINATION OF ABS SENSOR 5 the ABS sensor piece or the OR TONE WHEEL tone wheel contaminated by Remove the disc rotor or drum from hub in dirt or other foreign matter accordance with diagnostic trouble code CHECK DAMAGE OF ABS SENSOR OR TONE WHEEL Are there broken or damaged in the ABS sensor piece or the tone wheel ABS 49 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Ye s the runout less than 0 05 nm 0 0020 in CHECK TONE WHEEL RUNOUT Measure the tone wheel runout CHECK RESISTANCE OF ABS SENSOR 1 Turn the ignition switch OFF 2 Disconnect the connector from ABS sensor 3 Measure the resistance between ABS sen sor connector terminals Terminal Front RH No 1 No 2 Front LH No 1 No 2 Rear RH No 1 No 2
31. Refer to AUTOMATIC TRANSMISSION sepa rate publication AUTOMATIC TRANSMISSION for Front Differential Pub G0853ZE 2 MT MODEL For front differential of manual transmission refer to MT section Ref to MT 71 Front Differential Assembly DI 18 REAR DIFFERENTIAL DIFFERENTIALS 4 Rear Differential A REMOVAL 1 Set the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Move the select lever or gear shift lever to N 4 Release the parking brake 5 Loosen the wheel nuts 6 Jack up the vehicle and support it with sturdy racks 7 Remove the wheels 8 Remove the rear exhaust pipe and muffler Non turbo model Ref to 9 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHC 11 REMOVAL Muffler gt Turbo model lt Ref to EX DOHC TURBO 13 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX DOHC TURBO 14 REMOVAL Muffler gt 9 Remove the rear differential protector If equipped 10 Remove the front cover of rear differential mount 11 Remove the propeller shaft lt Ref to DS 14 REMOVAL Propeller Shaft gt 12 Remove the heat shield cover 13 Remove the clamps and bracket of parking brake cable 14 Remove the DOJ of rear drive shaft from rear differential using ST lt Ref to DI 37 REPLACE MENT Rear Differential Side Oil Seal gt ST 28099PA100 DRIVE SHAFT REMOVER B3M1628B 15 Secure th
32. WHEEL AND TIRE SYSTEM 1 SERVICE DATA Item Radial runout Steel wheel 1 5 mm 0 059 in Aluminum wheel 1 0 mm 0 039 in 2 ADJUSTING PARTS Wheel balancing Dynamic unbalance Less than 5 g 0 18 oz Balance weight part number Balance weight part number For aluminum wheel wean 23141GA462 5 g 0 18 2 23141GA472 10 g 0 35 2 Od a B PREPARATION TOOL 1 GENERAL PURPOSE TOOLS TOOL NAME REMARKS Air pressure gauge Used for measuring tire air pressure Dial gauge Used for measuring wheel runout WT 3 WHEEL TIRE SYSTEM 2 Tire A INSPECTION 1 Take stone glass nail etc off the tread groove 2 the tire CAUTION When replacing a tire make sure to use only the same size construction and load range as originally installed Avoid mixing radial belted bias or bias tires on the vehicle 1 when large crack on side wall damage or crack on tread is found 2 when the tread wear indicator appears as a solid band across the tread S4M0377A 1 Tread wear indicator 2 Tire tread 1 TIRE ROTATION If tires are maintained at the same positions for a long period of time uneven wear results There fore they should be periodically rotated This lengthens service life of tires CAUTION When rotating tires replace unevenly worn or damaged tires with new ones WT 4 STEEL WHEEL WH
33. e Apply specified power steering fluid to this ST and surface of piston ring to prevent seal from being damaged PS 33 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 10 Insert the rack assembly into the rack housing from cylinder side and remove ST after it has passed completely through oil seal NOTE Before inserting rack assembly apply a coat of specified power steering fluid to surfaces of ST and rack piston ST 926390001 COVER amp REMOVER 11 Fit ST1 and ST2 over the end of rack and in stall rack bushing ST1 926400000 GUIDE ST2 927660000 GUIDE CAUTION f burrs or nicks are found on this guide and rack shaft portion remove by filing Dip rack bushing in specified power steering fluid before installing and pay attention not to damage O ring and oil seal 54 0407 1 Rack bushing ASSY 12 Insert the rack stopper into the cylinder tube un til internal groove on cylinder side is aligned with external groove on rack stopper Turn the rack stopper with ST so that the rack stopper hole is seen through cylinder slits 13 Insert the rack stopper into the rack housing and wrap the circlip using a sharp pointed pliers to secure the rack stopper in position CAUTION Be careful not to scratch rack while winding cir clip Rotate the wrench another 90 to 180 after the end of circlip has been wrapped in 14 Fit the mounting rubber onto the rack housi
34. 2 Adjust the parking brake lt Ref to PB 12 AD JUSTMENT Parking Brake Assembly Rear Disc Brake gt BR 25 REAR DISC ROTOR BRAKE C INSPECTION 1 Set a dial gauge on the disc rotor Turn the disc rotor to check runout CAUTION Securely adjust the disc rotor to hub NOTE Make sure the dial gauge is set 5 mm 0 20 in ward of rotor outer perimeter e f the runout of disc rotor exceeds the limit check for abnormal free play at hub bearing and runout in the thrust direction lt Ref to DS 31 INSPECTION Rear Axle If the hub bearing is okay replace the disc rotor Disc rotor runout limit 0 07 mm 0 0028 in 2 Measure the disc rotor thickness If the thickness of disk rotor is below runout limit re place the disk rotor NOTE Make sure the micrometer is set 5 mm 0 20 in in ward of rotor outer perimeter Standard value 10 mm 0 39 in Service limit 8 5 mm 0 335 in BR 26 REAR DISC BRAKE ASSEMBLY BRAKE 7 Rear Disc Brake Assembly A REMOVAL CAUTION Do not allow brake fluid to come in contact with the vehicle body wipe off completely if spilled 1 Set the vehicle on the lift 2 Loosen the wheel nuts 3 Lift up the vehicle and remove the wheels 4 Disconnect the brake hose from caliper body as sembly 5 Remove the lock pin 6 Raise the caliper body and move it toward the vehicle center to separate it from support 7 Remove the support f
35. 7 8 0088 5 156 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK MOTOR RELAY IN ABSCM amp H U Measure the resistance between ABSCM amp H U terminals Terminals No 25 No 26 CHECK MOTOR OPERATION Operate the sequence control Ref to ABS 11 ABS Sequence Control NOTE Use the diagnosis connector to operate the se quence control CHECK POOR CONTACT IN CONNECTORS Turn the ignition switch to OFF CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Is the resistance more than 1 MQ Can the motor revolution noise buzz be heard when carrying out the sequence control Is there poor contact con nector between hydraulic unit relay box and ABSCM amp H U 5 the same diagnostic trouble code as in the current diagno sis still being output Are other diagnostic trouble codes being output ABS 157 Go to step 2 Go to step 3 Repair the con nector Replace the ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code Replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Replace the ABSCM amp H U Ref to A
36. 80 kg cm 1 040 1 137 psi 4 If it is not within the specified value replace the oil pump 3 Measure working pressure 1 Using STs measure the working pressure 2 Open the valve 3 Measure the working pressure of control valve by turning wheel from stop to stop ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099 010 ADAPTER HOSE A Service limit TURBO model 7 350 8 036 kPa 75 82 kg cm 1 067 1 165 psi Non TURBO model 7 164 7 840 kPa 73 80 kg cm 1 040 1 137 psi PS 68 4 If it is within the specified value measure the steering effort lt Ref to PS 78 MEASURE MENT OF STEERING EFFORT INSPECTION General Diagnostic Table gt If it is not within specified value replace the control valve itself or control valve and pinion as a single unit with new ones PS 69 POWER ASSISTED SYSTEM POWER STEERING RESERVOIR TANK POWER ASSISTED SYSTEM POWER STEERING 8 Reservoir Tank A REMOVAL 1 NON TURBO MODEL 1 Remove the air intake duct Ref to IN SOHC 7 REMOVAL Air Intake Duct 2 Drain the fluid from the reservoir tank 3 Disconnect the pipe D from the return hose and suction hose from the oil pump CAUTION e Do not allow fluid from the hose end to come into contact with pulley belt To prevent foreign matter from entering the hose and pipe cover the open ends of them with a clean cloth
37. CHECK INSTALLATION OF ABS SENSOR Turn the ignition switch to OFF Tightening torque 32 N m 3 3 kgf m 24 ft Ib CHECK ABS SENSOR GAP Measure the tone wheel to ABS sensor piece gap over entire perimeter of the wheel Front wheel 0 3 0 8 mm 0 012 0 031 in Rear wheel 0 7 1 2 mm 0 028 0 047 in ABSCM amp H U and ABS sensor Are the ABS sensor installation bolts tightened securely Tighten the ABS sensor installation bolts securely Go to step 8 Go to step 9 Go to step 10 Go to step 11 Is the gap within the specifica tions Adjust the gap NOTE Adjust the gap us ing spacers Part No 26755AA000 lf spacers cannot correct the gap re place worn sensor or worn tone wheel Replace the tone wheel Front lt Ref to ABS 21 Front Tone Wheel gt Rear lt Ref to ABS 22 Rear Tone Wheel gt Replace the ABS sensor and ABSCM amp H U Front Ref to ABS 14 Front ABS Sensor Rear Ref to ABS 18 Rear ABS Sensor and Ref to ABS 7 ABS Con trol Module and Hydraulic Control Unit ABSCM amp H U gt CHECK TONE WHEEL RUNOUT Measure the tone wheel runout Is the runout less than 0 05 mm 0 0020 in CHECK GROUND SHORT OF ABS SENSOR 1 Turn the ignition switch to ON 2 Measure the resistance between ABS sen sor and chassis ground Terminal Front RH No 1 Chassis g
38. EMI T 12 Transfer Clutch Pressure 0022222 13 Transfer Duty Solenoid and Valve Body 14 GENERAL DESCRIPTION TRANSFER CASE 1 General Description A NOTE For removal installation and inspection work refer to AT or MT section AT model lt Ref to AT 2 General Description gt MT model lt Ref to MT 2 General Description gt TC 2 TRANSFER CASE AND EXTENSION FOR MT TRANSFER CASE 2 Transfer Case and Extension for MT A NOTE For removal installation and inspection work refer to MT section lt Ref to MT 41 Transfer Case and Extension Case Assembly gt TC 3 TRANSFER CLUTCH AND EXTENSION FOR TRANSFER CASE 3 Transfer Clutch and Exten sion for AT A NOTE For removal installation and inspection work refer to AUTOMATIC TRANSMISSION a separate publication Pub GO853ZE TC 4 OIL SEAL 4 Oil Seal A NOTE For removal installation and inspection work refer to AT or MT section AT model lt Ref to AT 27 Extension Case Oil Seal gt MT model Ref to MT 36 Seal TC 5 TRANSFER CASE TRANSFER DRIVE GEAR MT TRANSFER CASE 5 Transfer Drive Gear MT A NOTE For removal installation and inspection work refer to MT section lt Ref to MT 45 Transfer Drive Gear gt TC 6 TRANS
39. F49 No 3 Chassis ground CHECK TCM 1 Turn the ignition switch to OFF 2 Connect all connectors to TCM 3 Turn the ignition switch to ON 4 Measure the voltage between TCM connec tor terminal and chassis ground Connector amp terminal NON TURBO MODEL B54 No 19 Chassis ground Is the resistance more than 1 MQ Is the voltage less than 1 V Is the voltage less than 1 V ABSCM amp H U Is the voltage between 10 and 15 V TURBO MODEL B55 No 21 4 Chassis ground Repair the 7 CHECK OPEN CIRCUIT OF HARNESS Is the voltage between 10 and Repair harness Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 3 Chassis ground Go to step 8 F49 No 31 Chassis ground CHECK POOR CONTACT IN CONNECTORS 15 there poor contact in con Repair the con Go to step 9 nectors between TCM and nector ABSCM amp H U CHECK ABSCM amp H U Is the same diagnostic trouble Replace the Go to step 10 1 Turn the ignition switch to OFF code as the current diagno ABSCM amp H U 2 Connect all connectors sis still being output Ref to ABS 7 3 Erase the memory ABS Control Mod 4 Perform the inspection mode ule and Hydraulic 5 Read out the diagnostic trouble code Control Unit 15 V connector between TCM and ABSCM amp H U
40. F49 No 6 Chassis ground CHECK BATTERY SHORT OF HARNESS Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 6 Chassis ground CHECK BATTERY SHORT OF HARNESS 1 Turn the ignition switch to ON 2 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 6 Chassis ground Is the voltage between 4 75 and 5 25 V Is the voltage less than 1 V Repair harness between G sensor and ABSCM amp H U Is the voltage less than 1 V Repair harness between G sensor and ABSCM amp H U ABS 91 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS ep eck esd 8 CHECK GROUND SHORT OF HARNESS Is the resistance more than 1 to step 9 Repair harness Measure the resistance between ABSCM amp H U 0 between G sensor connector and chassis ground and ABSCM amp H U Connector amp terminal Replace the F49 No 28 Chassis ground ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt CHECK G SENSOR 1 Turn the ignition switch to OFF 2 Remove the G sensor from vehicle 3 Connect the connector to G sensor 4 Connect the connector to ABSCM amp H U 5 Turn the ignition switch to ON 6 Measure the voltage betwee
41. Ye No 1 CHECK STEERING EFFORT Is the steering effort 31 4 N Go to step 2 Adjustment back 1 Stop the vehicle on a concrete road 3 2 kgf 7 1 Ib or less lash 2 Start the engine 3 ldle the engine 4 Install the spring scale on the steering wheel 5 Pull the spring scale at an right angle to the steering wheel and measure both right and left steering wheel effort NOTE When turning steering more quickly than nec essary from a direction to the other direction at an engine speed over 2 000 rpm steering effort may be heavy This is caused by flow charac teristic of oil pump and is not a problem CHECK STEERING EFFORT 1 Stop the engine 2 Pull the spring scale at an right angle to the steering wheel and measure both right and left steering wheel effort CHECK STEERING WHEEL EFFORT 1 Remove the universal joint 2 Measure the steering wheel effort CHECK STEERING WHEEL EFFORT Measure the steering wheel effort Is the steering effort 294 2 N 30 kgf 66 2 Ib or less Go to step 3 Adjustment Go to step 4 Check adjust and replace if neces Go to step 5 sary Check adjust and Go to step 6 Go to step 7 Replace with new one Is the maximum force steering wheel effort 2 26 0 23 kgf 0 51 Ib or less Is the fluctuation width 1 08 N 0 11 kgf 0 24 Ib or less replace if neces sary Replace with new one
42. nectors between ABSCM amp H U and ABS sensor Is the car telephone or the wireless transmitter properly installed Install the noise sources apart from the sensor har ness Go to step 6 Are noise sources such as an antenna installed near the sensor harness Is the resistance less than 0 5 CHECK SHIELD CIRCUIT 1 Turn the ignition switch to OFF 2 Connect all connectors 3 Measure the resistance between shield con nector and chassis ground Connector amp terminal DTC 26 B200 No 11 Chassis ground DTC 28 B200 No 3 Chassis ground NOTE For the DTC 22 and 24 Go to step 6 CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code Repair the shield harness Replace the ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code Go to step 9 Is the same diagnostic trouble Go to step 7 code as in the current diagno sis still being output CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary noise interference Are the ABS sensor installation bolts tightened securely C
43. 0 7 1 2 mm 0 028 0 047 in place worn pus or worn one wheel 7 PREPARE OSCILLOSCOPE Is an oscilloscope available 8 CHECK ABS SENSOR SIGNAL Is the oscilloscope pattern Go to step 12 Go to step 9 1 Raise all four wheels off ground smooth as shown in figure 2 Turn the ignition switch OFF 3 Connect the oscilloscope to the connector 4 Turn the ignition switch ON 5 Rotate the wheels and measure voltage at specified frequency Ref to ABS 17 WAVE FORM Control Module Signal NOTE When this inspection is completed the AB SCM amp H U sometimes stores the DTC 29 Connector amp terminal Front RH F95 No 1 No 2 Front LH F94 1 No 2 Rear RH B99 No 9 No 10 Rear LH B99 No 4 No 5 ABS 55 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Yes CHECK CONTAMINATION OF ABS SENSOR Is the ABS sensor piece or the Thoroughly OR TONE WHEEL tone wheel contaminated by remove dirt or Remove the disc rotor from hub dirt or other foreign matter other foreign mat ter Replace the ABS Go to step 11 sensor or tone wheel Front Ref to ABS 14 Front ABS Sensor Rear Ref to ABS 18 Rear ABS Sensor gt and Front lt Ref to ABS 21 Front Tone Wheel gt Rear lt Ref to ABS 22 Rear Tone Wheel gt Go to step 12 Go to step 10
44. 1 8 bolt 2 M12 bolt with max 3 M12 bolt with oil 4 M10 bolt 5 Remove the sub frame NOTE Loosen bolt 1 and leave a few threads caught then remove the bolts in the order of 2 3 4 5 and 6 FS 16 SUB FRAME FRONT SUSPENSION C INSPECTION 1 Check that there is no damage and distortion at the sub frame 2 Check that the bolts are tightened with the spec ified torque If there is looseness tighten to the specified torque NOTE The tightening torque differs by the color for bolt 3 Always verify the bolt color before checking tightening torque Tightening torque T1 34 N m 3 5 kgf m 25 ft lb 2 55 5 6 kgf m 41 ft lb T3 71 N m 7 2 kgf m 52 ft Ib T4 Dark green bolt 105 N m 10 7 kgf m 77 ft lb T4 Except dark green bolt 55 N m 5 6 kgf m 41 ft Ib FS 17 SUB FRAME FRONT SUSPENSION 3 Sub Frame B INSTALLATION A REMOVAL the reverse order of removal 1 Lift up the vehicle 2 Remove the under cover 3 Remove the bolt cover Tightening torque T1 34 N m 3 5 kgf m 25 ft lb T2 55 N m 5 6 kgf m 41 ft Ib T3 71 N m 7 2 kgf m 52 ft Ib Heplace the M12 bolt with a new one 1 M8 bolt 2 M12 bolt 3 M10 bolt C INSPECTION Check that there is no damage and distortion at the sub frame 5 Remove the sub frame NOTE Loosen bolt 1 and leave a few threads caught then remove the boits in the order
45. 1 1 C i FRONT FRONT ABS ABS REAR REAR SENSOR LH SENSOR RH ABS ABS SENSOR LH SENSOR RH 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 977281291017 1 2 124 25 2 0084 5 48 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Gk esd CHECK INSTALLATION OF ABS SENSOR the ABS sensor installation Go to step 2 Tighten the ABS Turn the ignition switch to OFF bolts tightened securely sensor installation Tightening torque bolts securely 32 N m 3 3 kgf m 24 ft lb Go to step 3 Adjust the gap NOTE Adjust the gap us ing spacer Part No 26755AA000 lf spacers cannot correct the gap re place worn sensor or wom tone wheel CHECK ABS SENSOR GAP 3 PREPARE OSCILLOSCOPE Is an oscilloscope available Measure the tone wheel to ABS sensor piece 4 CHECK ABS SENSOR SIGNAL Is the oscilloscope pattern gap over entire perimeter of the wheel 1 Raise all four wheels off ground smooth as shown in the fig Thoroughly Go to step 6 remove dirt or other foreign mat ter Front wheel 2 Turn the ignition switch OFF ure Replace the ABS Go to step 7 sensor or tone wheel Front Ref to ABS 14 Front ABS Sensor Rear Ref to ABS 18 Rear ABS Sensor and Front Ref to ABS 21 Front Tone Wheel Rear Ref to ABS 22 Rear Tone Wheel
46. 2 4 mm 0 08 0 16 in WARNING Always refer to Air Bag System before per forming airbag module service Ref to AB 12 CAUTION Driver s Airbag Module CAUTION Insert the roll connector guide pin into the guide hole on lower end of surface of steering wheel to prevent damage Draw out the airbag system connector horn connector and cruise control connectors from the guide hole of steering wheel lower end C INSPECTION 1 Check the steering wheel for deformation If the deformation is excessive replace the steering wheel 2 Check the splines on the steering wheel for dam age If the damage is excessive replace the steer ing wheel PS 19 UNIVERSAL JOINT POWER ASSISTED SYSTEM POWER STEERING 3 Universal Joint B INSTALLATION 1 Install the universal joint A REMOVAL 1 Align the cutout at serrated section of the 1 Remove the steering wheel lt Ref to PS 19 RE column shaft and yoke then insert the universal MOVAL Steering Wheel gt joint into the column shaft 2 Remove the universal joint bolts and then re move the universal joint CAUTION Scribe alignment marks on universal joint so that it can be reassembled at the original serra tion 1 Cutout 2 Yoke 3 Column shaft 4 Column shaft side 5 Gearbox side 2 Align the bolt hole on the gearbox side of universal joint with the cutout at the serrated section of gearbox assembly Lower the univer sal joint co
47. BRAKE 2 Front Brake Pad A REMOVAL 1 Set the vehicle on the lift 2 Loosen the wheel nuts 3 Jack up the vehicle and remove the front wheel 4 Remove the lock pin 5 Raise the caliper body 6 Remove the pad NOTE If the brake pad is difficult to remove proceed as follows 1 Remove the caliper body and fasten it provi sionally to coil spring 2 Remove the support 3 Place the support in a vise between wooden blocks B4M2230B 1 Support 2 Wooden blocks 4 Attach a rod of less than 12 mm 0 47 in dia to the shaded area of the brake pad and strike the rod with a hammer to drive brake pad out of place 4 2231 INSTALLATION 1 Apply a thin coat of Molykote 5880 Part No 26298 000 to the frictional portion between pad and pad clip 2 Apply a thin coat of Molykote AS880N Part No 26298 000 to the frictional portion between pad and pad inner shim 0100 3 Install the pads support 4 Install the caliper body on support Tightening torque Non turbo model 26 5 N m 2 70 kgf m 19 5 ft Ib Turbo model 37 3 8 kgf m 27 5 ft lb NOTE If itis difficult to push the piston during pad replace ment loosen the air bleeder to facilitate work 5 Install the front wheel BR 16 FRONT BRAKE PAD BRAKE C INSPECTION Check the pad thickness A BRO101 including back ee 75mm 0 295 n CAUTION
48. CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK GROUND CIRCUIT OF ABS RELAY 2 ee CHECK GROUND CIRCUIT ABSCM amp H U CHECK POOR CONTACT IN CONNECTORS Is the voltage more than 10 V Repair open circuit in harness between battery and relay holder connector Go to step 4 Go to step 6 Go to step 7 Go to step 8 Is the voltage more than 10 V Repair harness connector between battery ignition switch and ABS relay Repair open circuit between ABS relay and chassis ground Is the resistance less than 5 Q Is the resistance less than 10 Q Replace the ABS relay Is the voltage between 10 and 15 V Repair harness connector between battery ignition switch and ABSCM amp H U is the resistance less than 0 5 Q ground harness Go to step 9 Repair the con nector is there poor contact in con nectors between generator battery and ABSCM amp H U 5 the same diagnostic trouble code as in the current diagno sis still being output Go to step 10 Replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Go to step 11 ABS 127 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CH
49. CHECK INPUT VOLTAGE OF G SENSOR 1 Turn the ignition switch to OFF 2 Remove the console box 3 Disconnect the G sensor from body Do not disconnect connector 4 Turn the ignition switch to ON 5 Measure the voltage between G sensor con nector terminals Connector amp terminal Go to step 17 Repair harness connector between G sensor and ABSCM amp H U B292 1 3 CHECK OPEN CIRCUIT IN SENSOR OUT 15 the resistance between 4 3 Go to step 18 Repair harness PUT HARNESS AND GROUND HARNESS 4 9 connector 1 Turn the ignition switch to OFF between G sensor 2 Disconnect the connector from ABSCM amp and ABSCM amp H U H U 3 Measure the resistance between ABSCM amp H U connector terminals Connector amp terminal F49 No 6 No 28 CHECK G SENSOR Is the voltage between 2 1 and Go to step 19 Replace the G 1 Connect the connector to G sensor 2 5 V when G sensor is hori sensor Hef to 2 Connect the connector to ABSCM amp H U zontal ABS 23 G Sen 3 Turn the ignition switch to ON sor 4 Measure the voltage between G sensor con nector terminals Connector amp terminal B292 2 3 CHECK G SENSOR Is the voltage between 3 7 and Go to step 20 Replace the G Is the voltage between 0 5 and to step 21 Replace the G 0 9 V when G sensor is sensor Ref to inclined backwards to 90 ABS 23 G Sen sor gt ABS 172 Is the voltag
50. Chassis ground CHECK HARNESS CONNECTOR BETWEEN 15 the resistance between 1 Go to step 11 Replace the ABS sensor Front lt Ref to ABS 14 Front ABS Sen sor Hear Ref to ABS 18 Rear ABS Sensor Repair harness and 1 5 Is the voltage less than 1 V Repair harness between ABSCM amp H U and ABS sensor connector Go to step 13 between ABSCM amp H U and ABS sensor Go to step 14 Repair harness between ABSCM amp H U and ABS sensor Is the voltage less than 1 V Are the ABS sensor installation bolts tightened securely Go to step 15 Tighten the ABS sensor installation bolts securely ABS 108 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS 15 CHECK ABS SENSOR Is the gap within the specifica Go to step 16 Adjust the gap Measure the tone wheel to ABS sensor piece tions gap over entire perimeter of the wheel NOTE Adjust the gap us Front wheel ing spacers Part 0 3 0 8 0 012 0 031 in No 26755AA000 Rear wheel If spacers cannot 0 7 1 2 mm 0 028 0 047 in correct the gap re place the worn sensor or wom tone wheel Go to step 17 Replace the tone wheel Front Ref to ABS 21 Front Tone Wheel Rear Ref to ABS 22 Rear Tone Wheel Go to ste
51. EJ with LSD MODEL Type of gear Hypoid gear Es Number of gear 3 999 39 10 4 111 37 9 4 444 40 9 3 545 39 11 4 111 37 9 Oil capacity 0 8 0 0 8 US at 0 7 Imp qt Rear differential gear oi Identification Rear differential gear oil When replacing a rear differential assembly select Recommended the correct one according to the following figure CAUTION CAUTION Each oil manufacturer has its base oil and addi Using the different rear differential assembly tives Thus do not mix two or more brands causes the drive line and tires to drag or emit TEN abnormal noise when AWD is selected Classification GL 5 SAE Viscosity No and Application Temperature C 30 26 15 5 0 15 2530 F 22 15 5 23 32 59 77 86 c DRO0001 H3M1272A 1 SERVICE DATA Front and rear bearing preload al companion flange bolt N kgf Ib 2 ADJUSTING PARTS New bearin 19 6 28 4 Front and rear bearing preload at com g 2 0 2 9 kgf 44 6 4 Ib 4 Ib panion flange bolt hole 8 34 16 67 N 0 85 1 7 kgf 1 87 3 75 Ib Length 383695201 56 2 mm 2 213 in Preload adjusting spacer 572 mm 226210 DI 2 GENERAL DESCRIPTION DIFFERENTIALS Preload adjusting washer Pinion height adjusting shim Side gear backlash Side gear thrust washer Non Turbo model Side bearing standard width Side bearing retainer shim
52. Eliminate the cause of trouble 12 Check followings by referring to CHECK arti cle Excessive play in pulley shaft Ditch deflection of pulley e Resistance to rotation of pulley e Measurement of generated oil pressure PS 65 Replace with a new 2 Play of pulley shaft 1 Defect or burning of vane pump Oil pump Interior 2 Bend in the shaft or damage to bearing OIL PUMP Perform the following inspection procedures and repair or replace defective parts 1 Shaft bend 3 Shaft 4 Bearing damage 1 Wear and damage on sliding surfaces 2 Ridge wear on vane sliding grooves If light 7 Rotor leaks with vane in slit against light source Correct with oil stone If the damage is serious 3 Damage resulting from snap ring removal replace with a new cartridge assembly n accordance with the following table check all removed parts for wear and damage and make repair or Measure the radial play and axial play Measure the V ditch deflection If it is past the service limit replace the oil pump with a when turning with a string put around its pulley POWER ASSISTED SYSTEM POWER STEERING 2 Wear and damage on surfaces in contact with 4 Pressure plate Wear and damage on sliding surfaces Replace with a new one Damage on threads Replace with a new one replacement if necessary If any of t
53. Loosen the lock bolt and slider bolt and remove the power steering pump drive V belt 5 Disconnect the connector from the power steer ing pump switch POWER ASSISTED SYSTEM POWER STEERING 6 Disconnect the pipe C and suction hose from the oil pump CAUTION Do not allow fluid from the hose end to come into contact with pulley belt To prevent foreign matter from entering the hose cover the open ends of them with a clean cloth 1 Suction hose 2 PipeC 7 Remove the bolts which install power steering pump bracket 8 Place the oil pump bracket in a vise remove the two bolts from the front side of oil pump CAUTION Do not place oil pump bracket directly in the vise use soft pads and hold oil pump lightly to protect the pump 9 Remove the bolt from the rear side of oil pump PS 55 OIL PUMP POWER ASSISTED SYSTEM POWER STEERING 10 Disassemble the oil pump and bracket by in serting a screwdriver as shown in the figure B4M1661 2 TURBO MODEL 1 Remove the ground terminal from battery 2 Remove the pulley belt cover 3 Loosen the lock bolt and slider bolt and remove the power steering pump drive V belt 4 Disconnect the connector from the power steer ing pressure switch 5 Disconnect the pipe C and suction hose from the oil pump CAUTION Do not allow fluid from the hose end to come into contact with pulley belt To prevent foreign matter from
54. O ring 1 Front 2 Alignment mark 8 Install the rotor to the front casing with groove facing rearward 1 Rear 2 Groove 9 Install the 10 vanes into the rotor with their nose radius facing toward cam ring PS 62 OIL PUMP POWER ASSISTED SYSTEM POWER STEERING 12 Using STs press the retaining ring into the CAUTION shaft groove Make sure the retaining ring is fit in the second CAUTION groove of the shaft Discard retaining ring and replace with a new one NOTE Use ST2 bending its top edge slightly toward the inside ST1 34099AC030 INSTALLER RETAINING RING CAP ST2 34099AC040 INSTALLER RETAINING RING PIPE 1 First groove 2 Second groove 3 Shaft 4 Retaining ring 5b Hotor 13 Mount on pressure switch on front casing 14 With knock pin positions aligned install the rear cover CAUTION Loosely the tighten bolts in the sequence A B C and D shown in figure Then tighten in the same sequence Tightening torque 21 2 14 kgf m 15 5 ft lb 1 Shaft 2 Front casing 3 48 mm 1 89 in 4 Retaining ring 5 Block 1 Rear cover 15 Install the spring into the front casing Then with spool valve dipped in specified hydraulic oil in stall it into the front casing 16 Using a 5 mm dia round bar ensure that the valve moves smoothly PS 63 OIL PUMP POWER ASSISTED SYSTEM POWER STEERING 17 Set the O ring with grease appli
55. While depressing the brake pedal turn the steer ing wheel fully to the left and right With the steer ing wheel held at each fully turned position measure both the inner and outer wheel steering angle Steering angle Taner whee _ Inner wheel 34 05 11 5 6 55 11 5 Outer wheel 29 35 1 5 31 35 11 5 Turbo sedan and Rotate clockwise Right side Rotate counterclock Rotate counterclock Rotate clockwise 4 0192 Adjustment Turn the tie rod to adjust the steering angle of both inner and outer wheels CAUTION e Check the toe in e Correct the boot if it is twisted MS 1 Lock nut FS 13 WHEEL ALIGNMENT FRONT SUSPENSION 7 THRUST ANGLE Inspection 1 Position the vehicle on a level surface 2 Move the vehicle 3 to 4 meters directly forward 3 Determine the locus of both front and rear axles 4 Measure the distance L between center line of 3 When the left and right adjusting bolts are turned incrementally by one graduation in the same direc tion the thrust angle will change approximately 16 L is almost equal to 12 mm 0 472 in Thrust angle 02 20 loci of the axles Thrust angle Less than 20 when L is equal to or less than 15 mm 59 in 0 Hnc 54 03508 1 Center line of loci front axle 2 Center line of loci rear axle Adjustment 1 Make the thrust angle adjustments by tu
56. between battery ignition switch and ABSCM amp H U Go to step 10 30 to step 11 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output Proceed with the A temporary poor diagnosis corre contact sponding to the diagnostic trouble code ABS 64 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS ABS 65 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS U DTC 41 ABNORMAL ABS CONTROL MODULE DIAGNOSIS Faulty ABSCM amp H U TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT B4M1457 ABS 66 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Check Yes CHECK GROUND CIRCUIT OF ABSCM amp H U 116 the resistance less than 0 5 Go to step 2 Repair the ABSCM amp H U ground harness 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Measure the resistance between ABSCM amp H U and chassis ground Connector amp terminal F49 No 23 Chassis ground CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nectors between battery igni tion switch and ABSCM amp H U Is the car telephone or the wireless transmitter properly installed Repair the con nector Go to s
57. ector and ABSCM amp H U CHECK ABSCM amp H U s the same diagnostic trouble 3eplace the Go to step 7 1 Connect all connectors zode as in the current diagno ABSCM amp H U 2 Erase the memory sis still being output Ref to ABS 7 3 Perform the inspection mode ABS Control Mod 4 Read out the diagnostic trouble code ile and Hydraulic Zontrol Unit ABSCM amp H U CHECK ANY OTHER DIAGNOSTIC TROU Are other diagnostic trouble roceed with the A temporary poor BLE CODES APPEARANCE sodes being output liagnosis corre contact sponding to the liagnostic trouble 5 133 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS V DTC 42 POWER SUPPLY VOLTAGE TOO HIGH DIAGNOSIS Power source voltage of the ABSCM amp H U is high TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM BATTERY GENERATOR SWITCH IGNITION RELAY ER na 21 rA berer hehhehe EIS ELE oM mm mm NE oe 24 25 26 BROOB85 ABS 134 1 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS check e Is the voltage between 10 and Go to step 2 Repair the genera tor lt Ref to SC 13 Generator gt CHECK GENERATOR 1 Start the engine 2 idling after warm up 3 Measure the voltage between generator B terminal and chassis ground Terminal Genera
58. gauge indicate 3 432 kPa 35 kg cm 498 psi CAUTION Do not depress the clutch pedal 7 When the message Press YES is displayed press the YES key 8 Operation points will be displayed on the select monitor ABS 11 ABS SEQUENCE CONTROL ABS 3 CONDITIONS FOR ABS SEQUENCE CONTROL 4 km h Unit second 2 MPH or less 10 km h 6 MPH or less Speed of all wheels HIGH Terminal No 3 and No 6 Operational LOW guide line of iti i ON Ignition key switch OFF id Either Hl or LO possible if using select monitor 2 e pm rrr sequence control ON ABS warning light SORE HIGH Stop light switch op light switc Low E HIGH i AT ABS signa Low Valve relay FL outlet valve FL inlet valve Operational FR outlet valve pattern of sequence FR inlet valve Santol RR outlet valve RR inlet valve OFF RL outlet valve OFF RL inlet valve OFF Pump motor ON OFF Point A 11 i 1 Operational Pressure of master cylinder of Pressure of FL wheel cylinder y Pressure of FR wheel cylinder sequence Pressure of RR wheel cylinder 1 Pressure of RL wheel cylinder i 1 1 B4M1001A NOTE e When the select monitor is used control operation starts at point A The patterns from IGN key ON to the point A show that
59. i1 2 3 4 5 6 71819 10 11 12 13 14 15 1 2 3 4 1 5 6 7 8 9 0089 me E ON MM REO e etm NIMES e ABS 162 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Go to step 5 Go to step 3 Is the voltage between 10 and to step 5 Repair panies between stop light switch and ABSCM amp H U con CHECK OUTPUT OF STOP LIGHT SWITCH Is the reading ae NAME on USING SELECT MONITOR monitor display less than 1 5 1 Select Current data display amp Save on the V select monitor 2 Release the brake pedal 3 Read the stop light switch output in the select monitor data display CHECK OUTPUT OF STOP LIGHT SWITCH USING SELECT MONITOR 1 Depress the brake pedal 2 Read the stop light switch output in the select monitor data display Is the reading indicated on monitor display between 10 and 15 V CHECK OPEN CIRCUIT IN HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Depress the brake pedal 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 2 Chassis ground nector Is there poor contact in con nector between stop light switch and ABSCM amp H U Is the same diagnostic trouble code as in the current diagno sis still being output Repair the con Go to step 6 nector Replace
60. ignition switch and ABSCM amp H U Is the voltage between 10 and 15 V Repair the ABSCM amp H U ground harness Is the resistance less than 0 5 Replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Can the motor revolution noise buzz be heard when carrying out the sequence control Is there poor contact in con Repair the con Go to step 7 nector between generator bat nector tery and ABSCM amp H U Is the same diagnostic trouble Replace the Go to step 8 amp lt Ref to 5 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code code as in the current diagno sis still being output Are other diagnostic trouble codes being output A temporary poor contact ABS 161 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS AD DTC 54 STOP LIGHT SWITCH SIGNAL CIRCUIT MALFUNCTION DIAGNOSIS Faulty stop light switch TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM BATTERY 4 m q SBF 1 SBF 2 STOP LIGHT SWITCH 26 A al WITHOUT CRUISE CONTROL WITH CRUISE CONTROL F49 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT 5 112
61. pressed state the brake booster is faulty 54 0465 gt In the event of defective operation inspect the condition of the check valve and vacuum hose Replace them if faulty and conduct the test again e f no improvement is observed check precisely with gauges Operation check 1 With the engine off depress the brake pedal several times applying the same pedal force and make sure that the pedal height does not vary with each depression of the pedal 54 0466 1 When engine is stopped 2 When engine is started 2 With the brake pedal depressed start the en gine 3 As engine starts the brake pedal should move slightly toward the floor If no change occurs in the pedal height the brake booster is faulty NOTE If faulty check precisely with gauges Loaded air tightness check Depress the brake pedal while engine is running and turn off the engine while the pedal is still de pressed Keep the pedal depressed for 30 sec onds if no change occurs in the pedal height the brake booster is functioning normally if the pedal height increases it is faulty NOTE If faulty check precisely with gauges BR 40 BRAKE BOOSTER BRAKE 2 OPERATION CHECK WITH GAUGES CAUTION When checking operation be sure to securely apply the hand brake Checking with gauges Connect gauges as show
62. use a dynamic balancer Drive in the balance weight on both the top and rear sides of the rim 3 Some types of balancer can cause damage to the wheel Use an appropriate balancer when ad justing the wheel balance 4 Use genuine balance weights CAUTION e 55 g 1 94 oz weight used with aluminum wheel is not available Balance weights are available for use with any of 14 to 16 inch wheels 4 0053 1 Weight for aluminum wheel 2 Weight for steel wheel Service limit A Weight for steel wheel 2 16 mm 0 085 in Weight for aluminum wheel 4 5 mm 0 177 in WT 7 WHEEL AND TIRE SYSTEM 6 T type Tire A NOTE T type tire for temporary use is prepared as a spare tire CAUTION e Do not use tire chain with the T type tire Because of the smaller tire size a tire chain will not fit properly and will result in damage to the vehicle and the tire e Do not drive at a speed greater than 80 km h 50 MPH e Drive as slowly as possible and avoid pass ing over bumps B REPLACEMENT Refer to Removal and Installation of Steel Wheel for removal installation of T type tires Ref to WT 5 Steel Wheel gt CAUTION Replace with a conventional tire as soon as possible since the T type tire is only for tem porary use C INSPECTION 1 Check the tire inflation pressure Specification 420 kPa 4 2 kg cm 60 psi 2 Take the sto
63. 10 Using a puller remove the tie rod ball joint from the knuckle arm 11 On ABS equipped models remove the ABS sensor assembly and harness in advance 12 Remove the transverse link ball joint from the housing 13 After scribing an alignment mark on camber justing bolt head remove bolts which connect housing and strut and disconnect the housing from the strut B INSTALLATION 1 Install the transverse link ball joint to the hous Ing Tightening torque 49 N m 5 0 kgf m 36 ft lb 2 While aligning alignment mark on camber adjust ing bolt head connect the housing and strut CAUTION Use a new self locking nut Tightening torque 152 N m 15 5 kgf m 112 ft lb 3 Install the ABS sensor on the housing only ve hicle equipped with ABS Tightening torque 32 3 3 kgf m 24 ft lb 4 Install the disc rotor on the hub 5 Install the disc brake caliper on the housing Tightening torque 78 N m 8 kgf m 57 9 ft lb 6 Install the front drive shaft lt Ref to DS 32 IN STALLATION Front Drive Shaft gt 7 Connect the stabilizer link 8 Connect the tie rod end ball joint and knuckle arm with a castle nut and insert the cotter pin into the tie rod end Castle nut tightening torque Tighten to 27 0 N m 2 75 kgf m 19 9 ft lb and tighten further within 60 until cotter pin hole is aligned with a slot in the nut CAUTION When connecting do not hit cap at the bottom of tie
64. 15 0 in 15 20 in Thrust angle Thrust angle 09 20 Diameter of stabilizer 20 mm 13 17 mm 13mm 0 79in 0 51 0 67 in 0 51 in NOTE Front and rear toe ins and front camber be adjusted If the toe in or camber tolerance exceeds specifications adjust the toe in and camber to the middle value of specification The other items indicated in the specification ta ble cannot be adjusted If the other items exceeds specifications check the suspension parts and connections for deformities replace with new ones as required 4 2250 1 Front Positive Negative Toe out a1 a2 Each toe in angle RS 2 GENERAL DESCRIPTION REAR SUSPENSION RS 3 GENERAL DESCRIPTION REAR SUSPENSION B COMPONENT 500026 5 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Stabilizer Stabilizer bracket Stabilizer bushing Clamp Floating bushing Stopper Stabilizer link Rear lateral link Bushing C Bushing A Front lateral link Bushing B Trailing link rear bushing Trailing link Trailing link front bushing GENERAL DESCRIPTION 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Trailing link bracket Cap Protection Washer Rear crossmember Strut mount cap Strut mount Rubber seat upper Dust cover Coil spring Helper Rubber seat lower Damper strut Self locking nu
65. 3 5 6 8 9 10 11 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM Baffle plate DOJ Outer race DOJ Snap ring Inner race Ball Cage Circlip Boot band Boot DOJ Boot Non Turbo BU ASSY Turbo ASSY 12 13 14 15 16 17 18 19 20 21 22 DR0020 Baffle plate Tightening torque N m ft lb Oil seal IN No 2 1 13 1 3 9 4 Oil seal IN No 3 2 186 19 137 Housing Bearing ASSY Non Turbo model BJ Snap ring Turbo model EBJ Oil seal OUT Tone wheel With ABS Hub bolt Hub Axle nut DS 7 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM CAUTION e Wear working clothing including a cap protec tive goggles and protective shoes during opera tion e Remove contamination including dirt and corro sion before removal installation or disassembly e Keep the disassembled parts in order and tect them from dust or dirt e Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part on the vehicle is hot after running e Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or safety stands at the specif
66. 3 When the shoe return spring tension is exces sively weakened replace it taking care to identify upper and lower springs BR 31 REAR DRUM BRAKE DRUM BRAKE 9 Rear Drum Brake Drum A REMOVAL 1 Loosen the wheel nuts jack up the vehicle sup port it with rigid racks and remove the wheel 2 Release the parking brake 3 Remove the brake drum from brake assembly NOTE e If itis difficult to remove the brake drum remove the adjusting hole cover from back plate and then turn adjuster assembly pawls using a slot type screwdriver until the brake shoe separates from the drum Back plate Wheel cylinder Tightening direction Adjuster ASSY pawis Adjusting lever e If the brake drum is difficult to remove drive it out by installing an 8 mm bolt into bolt hole in brake drum B INSTALLATION 1 Set the outside diameter of brake shoes less than 0 5 to 0 8 mm 0 020 to 0 031 in in compari son with the inside diameter of brake drum 2 Install the drum 3 Install the rear wheel C INSPECTION 1 If the inside surface of brake drum is streaked correct the surface And if it is unevenly worn ta peringly streaked or the outside surface of brake drum is damaged correct or replace it 2 Measure the drum inner diameter Drum inner diameter L Standard 228 mm 9 in Service limit 230 6 mm 9 08 in BR 32 REAR DRUM BRAKE ASSEMBLY BRAKE 10 Rear Drum Brake Assembl
67. 6 Rear Differential Side Oil Seal A INSPECTION Make sure that there is no oil leakage from side oil seal If there is any oil leakage replace the oil seal B REPLACEMENT 1 Disconnect the ground terminal from battery 2 Move the select lever or gear shift lever to N 3 Release the parking brake 4 Loosen both wheel nuts 5 Jack up the vehicle and support it with rigid racks 6 Remove the wheels 7 Remove the rear exhaust pipe and muffler Non turbo model lt Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHC 11 REMOVAL Muffler gt Turbo model lt Ref to EX DOHC TURBO 13 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX DOHC TURBO 14 REMOVAL Muffler gt 8 Remove the DOJ of rear drive shaft from rear dif ferential 1 Remove the ABS sensor cable clamp and parking brake cable clamp from bracket H3M1397B A ABS sensor cable clamp B Parking brake cable guide 2 Remove the ABS sensor cable clamp from the trailing link lt 01 37 3 Remove the ABS sensor cable clamp and parking brake cable guide from the trailing link H3M1399B A ABS sensor cable clamp B Parking brake cable guide 4 Remove the rear stabilizer link 500017 5 Remove the bolts which secure the trailing link to the housing REAR DIFFERENTIAL SIDE OIL SEAL DIFFERENTIALS 7 Remove the DOJ from the rear differential 10 Remov
68. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM amp H U ABS B INSTALLATION 1 Install the ABSCM amp H U bracket Tightening torque 32 3 3 kgf m 24 ft lb 2 Install the ABSCM amp H U CAUTION Confirm that the specifications of the AB SCM amp H U conforms to the vehicle specifica tions Tightening torque 18 N m 1 8 kgf m 13 0 ft Ib 3 Connect the brake pipes to their correct AB SCM amp H U connections Tightening torque 15 N m 1 5 kgf m 10 8 ft lb 4 Using cable clip secure the ABSCM amp H U har ness to bracket 5 Connect the connector to the ABSCM amp H U CAUTION e Be sure to remove all foreign matter from in side the connector before connecting e Ensure that the ABSCM amp H U connector is se curely locked 6 Install the air intake duct Non turbo model Ref to IN SOHC 7 INSTALLATION Air Intake Duct gt Turbo model Het to IN DOHC TURBO 8 INSTALLATION Air Intake Duct gt 7 Bleed air from the brake system lt Ref to BR 46 Air Bleeding gt C INSPECTION 1 Check the connected and fixed condition of con nector 2 Check the specifications of the mark with AB SCM amp H U Wark BROO51 1 CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE 1 Lift up the vehicle and remove wheels 2 Disconnect the air bleeder screws from the FL and FR caliper bodies 3 Connect two pressure gauges to the FL and FR caliper bodies C
69. ABS sensor piece or the OR TONE WHEEL tone wheel contaminated by Remove the disc rotor or drum from hub in dirt or other foreign matter accordance with diagnostic trouble code CHECK DAMAGE OF ABS SENSOR OR TONE WHEEL Thoroughly remove dirt or other foreign mat ter Replace the ABS sensor or tone wheel Front Ref to ABS 14 Front ABS Sensor Hear Ret to ABS 18 Rear ABS Sensor and Front Ref to ABS 21 Front Tone Wheel Hear Ref to Go to step 13 ABS 22 Rear Go to step 14 Tone Wheel CHECK TONE WHEEL RUNOUT Is the runout less than 0 05 Go to step 15 Replace the tone Measure the tone wheel runout mm 0 0020 in wheel Front lt Ref to ABS 21 Front Tone Wheel gt Rear lt Ref to ABS 22 Rear Tone Wheel gt CHECK RESISTANCE OF ABS SENSOR Is the resistance between 1 Go to step 16 Replace the ABS 1 Turn the ignition switch OFF and 1 5 kQ sensor Front 2 Disconnect the connector from ABS sensor 3 Measure the resistance between ABS sen sor connector terminals Terminal Front RH No 1 No 2 Front LH No 1 No 2 Rear RH No 1 No 2 Rear LH 1 No 2 CHECK GROUND SHORT OF ABS SENSOR Is the resistance more than 1 Go to step 17 Measure the resistance between ABS sensor and chassis ground Terminal Front RH No 1 Chassis ground Front LH No 1 Chassis ground Rear RH No 1 Chassis ground Re
70. ABSCM amp H U ABS 75 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output Proceed with the A temporary poor diagnosis corre contact sponding to the diagnostic trouble code ABS 76 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS X DTC 51 ABNORMAL VALVE RELAY DIAGNOSIS e Faulty valve relay TROUBLE SYMPTOM e ABS does not operate ABS 77 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY SBF 3 SBF 1 OAD me 1 to ot e No 8 IQ IGNITION SWITCH RELAY HOLDER ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SOLENOID VALVE FL INLET FL OUTLET FR INLET FR OUTLET RL INLET RL OUTLET RR INLET OUTLE PUMP MOTOR 8 e 7 8 9 13 16 El 20 28 0087 17 18 19 20 21 22 _ ___ 27282930131 23 24 25 26 ABS 78 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS o No 1 CHECK INPUT VOLTAGE OF RELAY HOLD Is the voltage more than 10 V to step 2 Repair open circuit ER in harness 1 Turn the ignition switch to OFF between battery 2 Remove the fuse and relay holder 3 Measure the voltage between ABS relay connector connector and chassis gr
71. ABSCM amp H U ABS sensor Brake piping ABSCM amp H U mount bushing ABS sensor Master cylinder Noise from front of vehicle Brake caliper amp piston pads rotor Brake piping Brake booster amp check valve Suspension play or fatigue ABS sensor Brake caliper amp piston pads rotor Noise from rear of vehicle Parking brake Brake piping Suspension play or fatigue Vibration and or noise while driving on slippery roads ABS 184 gg 2 ol loc dE d General Description PER 2 Front D ETT 16 Front DISC ROO 18 Front Disc Brake 19 Heg Brake 24 Rear Disc BOLOEu Er pde DEL aa OU aM e 25 Rear Disc Brake Assembly 27 Rear Drum Brake Sho er ost RE Heu 30 Hear Dr m Brake DELI 32 Rear Drum Brake a uet 33 Master dete sued fecit Dua de E EE 36 Brake BOOST PV 38 T T 43 Brake Fuld E Air Bleeding Brake Hose
72. CIRCUIT S INABSCM amp H U FRONT LH NOTE For the diagnostic procedure refer to DTC 37 lt Ref to ABS 57 DTC 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR LH Diagnostics Chart with Diagnosis Connector O DTC 35 ABNORMAL INLET SOLENOID VALVE CIRCUIT S INABSCM amp H U REAR RH NOTE For the diagnostic procedure refer to DTC 37 lt Ref to ABS 57 DTC 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT S ABSCM amp H U REAR LH Diagnostics Chart with Diagnosis Connector P DTC 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR LH DIAGNOSIS e Faulty harness connector Faulty inlet solenoid valve in ABSCM amp H U TROUBLE SYMPTOM ABS does not operate ABS 57 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY GENERATOR IGNITION SWITCH RELAY Y C 0085 5 58 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Po Step 1 CHECK INPUT VOLTAGE OF RELAY HOLD Is the voltage more than 10 V Go to step 2 Repair open circuit ER 1 Turn the ignition switch to OFF 2 Remove the fuse 3 Measure the voltage between ABS relay connector and chassis ground Connector amp terminal B225 No 5 Chassis ground 2 CHECK RELAY HOLDER is the fuse blown out Replace the fuse Go to step 3
73. DIAGNOSTIC TROU BLE CODES APPEARANCE Is the same diagnostic trouble code as in the current diagno sis still being output Are other diagnostic trouble codes being output ABS 80 Replace the Go to step 12 ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Proceed with the diagnosis corre sponding to the diagnostic trouble code A temporary poor contact DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Y DTC 52 ABNORMAL MOTOR AND OR MOTOR RELAY DIAGNOSIS e Faulty motor Faulty motor relay e Faulty harness connector TROUBLE SYMPTOM ABS does not operate ABS 81 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM e 2 BATTERY SBF 1 pQ SBF 4 Ga IGNITION SWITCH ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SOLENOID VALVE FL INLET FL OUTLET FR INLET FR OUTLET RL INLET HR INLET RR OUTLE PUMP MOTOR 9 19 34 35 36 10 18 0088 11213141516 7 8 9 11211345 27 5 82 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS to M Is the voltage between 10 and 15 CHECK INPUT VOLTAGE ABSCM amp H U 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Turn the ignit
74. DIAGNOSTICS WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR om m m m e m a S BRO0090 ABS 170 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check Yes No CHECK OUTPUT OF SENSOR USING SE 5 the G sensor output onthe 3o to step 2 Go to step 5 LECT MONITOR onitor display between 2 1 1 Select Current data display amp Save on the ind 2 5 V when the G sensor select monitor horizontal position 2 Read the G sensor output in select monitor data display CHECK POOR CONTACT IN CONNECTORS 5 there poor contact in con between ABSCM amp H U ind G sensor 5 the same diagnostic trouble 3eplace the ode as in the current diagno BSCM amp H U is still being output Ref to ABS 7 ABS Control Mod ile and Hydraulic ontrol Unit amp gt roceed with the liagnosis corre sponding to the jiagnostic trouble 30 to step 11 Repair harness connector between G senso and ABSCM amp H U the con vector Go to step 4 A temporary poor contact CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE re oth
75. DISASSEMBLING 1 Remove mud and dirt from the surface of brake master cylinder 2 Prepare the tools necessary for disassembly op eration and arrange them neatly on work bench 3 Clean the work bench 2 DISASSEMBLING PROCEDURE 1 Remove the pin with drift pin which secures the reserve tank to master cylinder 2 Remove the cylinder pin with magnetic pick up tool while pushing in primary piston with ABS 54 0123 1 Cylinder Piston may jump out from master cylinder 4 Extract the primary piston assembly and second ary piston assembly CAUTION Do not disassemble the piston assembly otherwise the spring set value may be changed e Use brake fluid or methanol to wash inside wall of cylinder pistons and piston cups Be careful not to damage parts when washing If methanol is used for washing do not dip rub ber parts such as piston cups in it for more than 30 seconds otherwise they may become swelled BR 36 Mum Ww SR GE SO MEY eis grt e 0 4 2 MASTER CYLINDER BRAKE D ASSEMBLY 1 PRECAUTIONS FOR ASSEMBLING 1 When assembling be sure to use recommended brake fluid 2 Ensure that the inside wall of cylinder pistons and piston cups are free from dirt when assem bling 3 Be extremely careful not to damage scratch or dent cylinder inside wall pistons and piston cups 4 Do not drop the parts Never attempt to use any
76. Front and rear bearing preload For new bearing 19 6 28 4 2 0 2 9 kgf 4 4 6 4 Ib at companion flange bolt hole For used bearing 8 34 16 67 N 0 85 1 7 kgf 1 87 3 75 Ib at companion flange hole 53 0518 Thickness mm in Preload adjusting washer 383795200 Preload adjusting spacer 383695204 56 8 2 236 383695205 57 0 2 244 383695206 57 2 2 252 DI 25 REAR DIFFERENTIAL DIFFERENTIALS 3 Adjusting drive pinion height Adjust the drive pinion height with shim installed between rear bearing cone and the back of pinion gear 1 Install ST1 ST2 and ST3 as shown in the figure and apply the specified preload on the bearings Front and rear bearing preload For new bearing 19 6 28 4 N 2 0 2 9 kgf 4 4 6 4 Ib at companion flange bolt hole For used bearing 8 34 16 67 0 85 1 7 kgf 1 87 3 75 Ib at companion flange bolt hole Adjusting preload for front and rear bearings NOTE At this time install a pinion height adjusting shim which is temporarily selected or the same as that used before Measure and record the thickness 511 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE ST3 398507703 DUMMY COLLAR S3M0518B A Pinion height adjusting shim 2 Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge NOT
77. Front crossmember 17 Dust seal Tightening torque N m kgf m ft lb 2 Bolt ASSY 18 Strut mount T1 20 2 0 14 5 3 Housing 19 Spacer T2 25 2 5 18 1 4 Washer 20 Upper spring seat 30 3 1 22 5 Stopper rubber Rear 21 Rubber seat 74 34 3 5 25 6 Rear bushing 22 Dust cover T5 40 4 1 30 7 Stopper rubber Front 23 Helper 6 45 4 6 33 8 Ball joint 24 Coil spring T7 50 5 1 37 9 Transverse link 25 Damper strut T8 55 5 6 41 10 Cotter pin 26 Adjusting bolt T9 71 7 2 52 11 Front bushing 27 Castle nut T10 100 10 2 74 12 Stabilizer link Except sedan turbo 28 Self locking nut 11 lt Ref to FS 17 INSPECTION model 29 Sub frame Sub Frame gt 13 Clamp 30 Cover 712 175 17 8 129 14 Bushing 31 Clip 113 190 19 4 140 15 Stabilizer 32 Stabilizer link Sedan turbo model 714 250 25 5 184 16 Jack up plate FS 5 GENERAL DESCRIPTION FRONT SUSPENSION C CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during opera tion e Remove contamination including dirt and corro sion before removal installation or disassembly Keep the disassembled parts in order and pro tect them from dust or dirt e Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement e Use SUBARU genuine grease etc or the equiv
78. H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Proceed with the diagnosis corre sponding to the diagnostic trouble code CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output ABS 87 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS ABS 88 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS AA DTC 56 ABNORMAL G SENSOR OUTPUT VOLTAGE DIAGNOSIS e Faulty sensor output voltage TROUBLE SYMPTOM ABS does not operate ABS 89 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR Ga HT2TSTATSTST T8 TS TT 516 BROO90 ABS 90 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Check Yes Have the wheels been turned The ABS is nor freely such as when the vehicle mal Erase the is lifted up or operated ona diagnostic trouble rolling road code Does the vehicle specification Replace the CHECK ALL FOUR WHEELS FOR FREE TURNING Go to step 2 CHECK SPECIFICATIONS OF ABSCM amp H U Go to step 3 Ch
79. H U and ABS sensor Is the same diagnostic trouble code as in the current diagno sis still being output CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Replace the ABSCM amp H U Go to step 21 Proceed with the diagnosis corre sponding to the diagnostic trouble code Are other diagnostic trouble codes being output A temporary poor contact NOTE Check harness and connectors SCM amp H U ABS sensor and ABS 109 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS G DTC 22 FRONT RIGHT ABNORMAL ABS SENSOR SIGNAL NOTE For the diagnostic procedure refer to DTC 28 lt Ref to ABS 111 DTC 28 REAR LEFT ABNORMAL ABS SENSOR SIGNAL Diagnostics Chart with Subaru Select Monitor gt H DTC 24 FRONT LEFT ABNORMAL ABS SENSOR SIGNAL NOTE For the diagnostic procedure refer to DTC 28 lt Ref to ABS 111 DTC 28 REAR LEFT ABNORMAL ABS SENSOR SIGNAL Diagnostics Chart with Subaru Select Monitor gt I DTC 26 REAR RIGHT ABNORMAL ABS SENSOR SIGNAL NOTE For the diagnostic procedure refer to DTC 28 lt Ref to ABS 111 DTC 28 REAR LEFT ABNORMAL ABS SENSOR SIGNAL Diagnostics Chart with Subaru Select Monitor gt ABS 110 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR A
80. H U solenoid valve e ABS sensor e Brake pads e Tire specifications tire wear and air pressures Incorrect wiring or piping connections e ABSCM amp H U solenoid valve Brake pads Air in brake line Tire specifications tire wear and air pressures e incorrect wiring or piping connections ABSCM amp H U solenoid valve motor e ABS sensor e Incorrect wiring or piping connections ABSCM amp H U solenoid valve e ABS sensor Master cylinder Brake caliper amp piston e Parking brake Axle amp wheels Brake pedal play Long brake pedal stroke 4 Suspension play or fatigue reduced damping Vehicle pitching Incorrect wiring or piping connections Road surface uneven ABSCM amp H U solenoid valve e ABS sensor e Brake caliper amp piston pads Tire specifications tire wear and air pressures Incorrect wiring or piping connections e Road surface uneven Vehicle pulls to either side Vehicle instability during braking Vehicle spins Long braking stopping distance Wheel locks Brake dragging Poor braking Unstablie or uneven braking ABS 183 GENERAL DIAGNOSTICS TABLE ABS DIAGNOSTICS Probable faulty unisipars e Incorrect wiring or piping connections Excessive pedal vibration Jo PIS Road surface uneven ABSCM amp H U mount bushing Noise from
81. INSPEC TION Steering Gearbox gt Readjust back lash and if ineffec tive replace bad parts Readjust back lash and if ineffec tive replace bad parts Steering effort is normal PS 78
82. NON CON Controlled Controlled TROLLED Diagnostics Chart with Subaru Select Monitor 44 ABS AT control Con ABS AT control Con Ref to ABS 140 DTC 44 ABS AT CONTROL CONTROLLED trolled trolled Diagnostics Chart with Subaru Select Monitor Ref to ABS 143 DTC 51 VALVE RELAY MALFUNCTION Diag Valve relay malfunction Valve relay malfunction nostiesGhart with Subarit Select Monitors Ref to ABS 147 DTC 51 VALVE RELAY ON FAILURE Diagnos Valve relay ON failure Valve relay ON failure Subaru Select Monitor 52 Open circuit in motor Open circuit in motor lt Ref to ABS 151 DTC 52 OPEN CIRCUIT IN MOTOR RELAY CIR relay circuit relay circuit CUIT Diagnostics Chart with Subaru Select Monitor gt lt Ref to ABS 155 DTC 52 MOTOR RELAY FAILURE Diagnos Motor relay ON failure Motor relay ON failure tics Chart with Subaru Select Monitors 55 d MotsEmaltunenon Maiermalunetion Ref to ABS 1 59 DTC 52 MOTOR MALFUNCTION Diagnostics Chart with Subaru Select Monitor 54 Stop light switch signal Stop light switch signal Ref to ABS 162 DTC 54 STOP LIGHT SWITCH SIGNAL CIRCUIT circuit malfunction circuit malfunction MALFUNCTION Diagnostics Chart with Subaru Select Monitor G sensor circuit G sensor circuit SOR CIRCUIT Diagnostics Chart with Subaru Select Monitor Ref to ABS 169 DTC 56 BATTERY SHORT IN G SENSOR CIR Sor circuit Sor circuit CUIT Diagnostics Chart with Suba
83. Operate the sequence control Ref to ABS 11 ABS Sequence Control NOTE Use the diagnosis connector to operate the se quence control Can motor revolution noise Go to step 12 buzz be heard when carrying out the sequence control Heplace the 5 lt Ref to ABS 7 ABS Control ule and Hydraulic Control Unit ABSCM amp H U Go to step 13 CHECK POOR CONTACT IN CONNECTORS Turn the ignition switch to OFF Is there poor contact in con nector between generator bat tery and ABSCM amp H U Is the same diagnostic trouble code as in the current diagno sis still being output Repair the con nector CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code Heplace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Are other diagnostic trouble Proceed with the A temporary poor codes being output diagnosis corre contact sponding to the diagnostic trouble Go to step 14 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE code ABS 84 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS ABS 85 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS tas Z DTC 54 ABNORMAL STOP LIGHT SWITCH DIAGNOS
84. Pipe 2 Pipe D 1 Connect the pipe D to oil tank 2 Install the pipe C to oil pump CAUTION Use a new gasket Tightening torque 39 N m 4 0 kgf m 28 9 ft lb 3 Tighten bolts fixing pipe C and D Tightening torque 13 N m 1 3 kgf m 9 4 ft lb PS 49 PIPE ASSEMBLY POWER ASSISTED SYSTEM POWER STEERING 3 Temporarily connect the pipes C and D to the pipes on the gearbox side S4M0438A 1 Return hose 2 Pressure hose 3 Approx 30 mm 1 18 in 4 5 6 Pipe D 7 Pipe on gearbox side 4 Temporarily install the clamp E on the pipes and D CAUTION Ensure that the letter 8 on each clamp are di agonally opposite each other as shown in fig ure 1 Clamp E 2 PipeC 5 Tighten the clamp E firmly Tightening torque 7 4 N m 0 75 kgf m 5 4 ft Ib 6 Tighten the joint nut Tightening torque 15 N m 1 5 kgf m 10 8 ft Ib 7 Connect the pipes A and B to the four pipe joints of gearbox Connect the upper pipe B first and low er pipe second Tightening torque 13 N m 1 3 kgf m 9 4 ft Ib S4M0381A 1 Pipe 2 Pipe 8 Install the jack up plate 9 Install the air intake duct Non TURBO model Ref to IN SOHC 7 INSTALLATION Air Intake Duct 10 Install the air intake duct air intake boot and air cleaner upper cover TURBO model Ref to IN DOHC TURBO 7 INSTALLATION Air Cleaner and Ref to I
85. SENSOR 60 mV A 0 excel AJ Standard output voltage When it is 20 Hz Oscilloscope To terminal 33 nF 20 To terminal 4 1141 5 17 REAR ABS SENSOR ABS 5 Rear ABS Sensor B INSTALLATION 1 ily i ll th AB REMOVAL y install the rear ABS sensor on bac 1 Disconnect the ground terminal from battery CAUTION 2 Jack up the vehicle support it with rigid racks and remove the wheel 3 Remove the rear seat and disconnect the rear ABS sensor connector 4 Remove the rear sensor harness bracket from rear trailing link and bracket 5 Remove the rear ABS sensor from back plate Be careful not to strike the ABS sensor s pole piece and tone wheel s teeth against adjacent metal parts during installation 1 Rear ABS sensor 2 install the rear sensor harness on rear trailing link 1 Rear ABS sensor Tightening torque 32 3 3 kgf m 24 ft lb 1 Rear sensor harness 2 Trailing link ABS 18 REAR ABS SENSOR ABS 3 Place a thickness gauge between the ABS sen sors and tone wheel s tooth face After standard clearance is obtained over the entire perimeter tighten the ABS sensor on rear arm to specified torque ABS sensor standard clearance 0 7 1 2 mm 0 028 0 047 in Tightening torque 32 N m 3 3 kgf m 24 ft Ib CAUTION Check the marks on the harness to make sure that no distortion exists RH White LH Yellow NOTE If the clea
86. ST1 and ST2 PS 38 STEERING GEARBOX 8 Put ST3 over pinion and insert oil seal then force fit oil seal into housing using 574 ST1 926370000 INSTALLER A ST2 34099FA100 STAND BASE ST3 926360000 INSTALLER ST4 927620000 INSTALLER B LLIT i Ep lt gt 74 54 0404 1 Oil seal NOTE Apply the specified power steering fluid to the oil seal and ST3 being careful not to damage oil seal lip Push the oil seal until ST3 contacts housing end face 9 Remove ST3 and fit backing washer POWER ASSISTED SYSTEM POWER STEERING 10 Force fit ball bearing using ST3 ST1 926370000 INSTALLER ST2 34099FA100 STAND BASE INSTALLER B ST3 927640000 54 0405 1 Ball bearing 2 Backing washer NOTE Be careful not to tilt ball bearing during installation 11 Install the snap ring using snap ring pliers NOTE Rotate the snap ring to check for proper installa tion 12 Apply the specified grease to the dust cover 54 0156 1 Dust cover 13 Install the dust cover on the valve assembly 14 Apply genuine grease to the pinion gear and bearing of valve assembly PS 39 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 15 Install the gasket on the valve assembly Insert the valve assembly into the place while facing rack teeth toward pinion CAUTION Be sure to use a new gasket NOTE Do not allow
87. Sensor and Front Hef to ABS 21 Front Tone Wheel Rear Ref to ABS 22 Rear Tone Wheel Go to step 12 CHECK DAMAGE OF ABS SENSOR OR TONE WHEEL Are there broken or damaged teeth in the ABS sensor piece or the tone wheel the runout less than 0 05 mm 0 0020 in CHECK TONE WHEEL RUNOUT Measure the tone wheel runout Heplace the tone wheel Front Ref to ABS 21 Front Tone Wheel Rear Ref to ABS 22 Rear Tone Wheel Go to step 13 CHECK ABSCM amp H U 1 Turn the ignition switch to OFF 2 Connect all connectors 3 Erase the memory 4 Perform the inspection mode 5 Read out the diagnostic trouble code Is the same diagnostic trouble code as in the current diagno sis still being output Heplace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary poor contact ABS 120 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS L DTC 31 FRONT RIGHT INLET VALVE MALFUNCTION NOTE For the diagnostic procedure refer to DTC 37 lt Ref to ABS 121 DTC 37 REAR LEFT INLET VALVE MAL FUNCTION Diagnostics Cha
88. U 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Run the engine at idle 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 1 Chassis ground F49 24 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 23 Chassis ground CHECK VALVE RELAY IN ABSCM amp H U Measure the resistance between ABSCM amp H U and terminals Terminals No 23 No 24 Is the resistance less than 10 2 Is the voltage between 10 and 15 V Is the resistance less than 0 5 Q Is the resistance more than 1 MQ Measure the voltage between ABS relay con nector and chassis ground Connector amp terminal B264 No 1 Chassis ground CHECK GROUND CIRCUIT OF ABS RELAY ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Go to step 11 15 there poor contact in con nectors between generator battery and ABSCM amp H U ABS 79 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER
89. alent Do not mix grease etc with that of another grade or from other manufacturers e Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Apply grease onto sliding or revolution surfaces before installation Before installing O rings or snap rings apply suf ficient amount of grease to avoid damage and de formation Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice FS 6 GENERAL DESCRIPTION FRONT SUSPENSION D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927380002 ADAPTER Used as an adapter for camber amp caster gauge when measuring camber and caster 1 28199 PLATE gt 2 28199AC010 BOLT 8 B4M2378A 927680000 INSTALLER amp Used for replacing transverse link bushing REMOVER SET B4M2385 927760000 STRUT MOUNT SOCKET B4M2384 2 GENERAL PURPOSE TOOLS Used for wheel alignment measurement Used for wheel alignment measurement sed fortoe in measurement Used for damper strut measurement e Used for disassembling and assembling strut and shock mount FS 7 WHEEL ALIGNMENT FRONT SUSPENSION 2 Wheel Alignment A INSPECTION Check adjust and or measure wheel alignment in accordance with procedures indicated in figure WHEEL ARCH HE
90. and press it until plunger end sur face contacts trailing link end surface SPECIFIED lubricant TIRE LUBE 1 3 1 S4M0360A B4M0224B 1 Press 2 Front bushing 3 Trailing link CAUTION Install the front bushing in proper direction as shown in the figure 1 Press S4M0361A RS 13 REAR TRAILING LINK REAR SUSPENSION 2 Press the ST pluger until bushing flange pro 3 Turn the trailing link upside down Press the ST trudes beyond trailing link plunger in the direction opposite that outlines in the ST 927730000 INSTALLER amp REMOVER former procedure until bushing is correctly posi SET tioned in trailing link ST 927730000 INSTALLER amp REMOVER SET B4M0195B B4M0196B 1 Plunger 2 Flange 1 Press 2 Plunger 4 Install the housing lt Ref to DS 26 INSTALLA TION Rear Axle gt E INSPECTION Check the trailing links for bends corrosion or dam age RS 14 REAR STRUT 5 Rear Strut A REMOVAL 1 Remove the rear seat cushion and backrest Sedan model 2 Remove the strut cap of quarter trim Wagon model 3 Loosen the rear wheel nuts 4 Jack up the vehicle support it with safety stands rigid racks and remove the rear wheels 5 Remove the brake hose clip and remove the brake hose from rear strut 1 Brake hose clip 2 Brake hose 6 Remove the bolts which secure rear strut to housing 7 Remove the nuts sec
91. and support it with study racks 7 Remove the wheels 8 Remove the rear exhaust pipe and muffler Non turbo model lt Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHC 11 REMOVAL Muffler gt Turbo model lt Ref to EX DOHC TURBO 13 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX DOHC TURBO 14 REMOVAL Muffler gt 9 Remove the rear differential protector equipped 10 Remove the rear differential front member NOTE When removing the rear differential front member work the removal procedure as rear differential lt Ref to DI 19 REMOVAL Rear Differential gt 11 Remove the differential rear member B INSTALLATION To install reverse the removal sequence 1 Position the front member on body by passing it under parking brake cable and securing to rear dif ferential NOTE When installing the rear differential front member do not confuse the installation seqence of the stop per 2 Insert the DOJ of rear drive shaft into rear differ ential lt Ref to DI 37 REPLACEMENT Rear Dif ferential Side Oil Seal gt CAUTION Before inserting replace the differential side oil seal with a new one ST 28099PA090 SIDE OIL SEAL PROTEX TOR 3 Installing procedure hereafter is in the reverse order of removal C INSPECTION 1 Check the rear differential member for damage bend or corrosion If damage bend or corrosion is excessive replace the
92. brake fluid to the required level MAX lev el of reservoir tank 12 As a final step test run the vehicle at low speed and apply brakes relatively hard 2 to 3 times to en sure that brakes provide normal braking action on all four wheels without dragging and uneven brak ing BR 47 BRAKE HOSE BRAKE 16 Brake Hose A REMOVAL 1 FRONT BRAKE HOSE 1 Separate the brake pipe from brake hose Always use flare nut wrench and be careful not to deform flare nut B4M1843B 1 Brake hose 2 Brake pipe 2 Pull out the clamp to remove the brake hose 3 Remove the bolt at strut and union bolt 2 REAR BRAKE HOSE 1 Separate the brake pipe from brake hose NOTE Always use flare nut wrench and be careful not to deform flare nut 1 Brake hose clip 2 Brake hose 3 Brake pipe 2 Unscrew the brake hose flare nut and discon nect the brake hose 3 Pull out the clamp to remove the brake hose B INSTALLATION 1 FRONT BRAKE HOSE 1 Route the end of brake hose on caliper side through hole in brake hose bracket at strut location 2 Tighten the end of brake hose at caliper using a union bolt Tightening torque Union bolt 18 1 8 kgf m 13 0 ft Ib 3 Secure the middle fitting of brake hose to bracket at strut location using a clamp 4 Position the disc in straight forward direction and route the brake hose through hole in bracket on wheel apron side CAUTION Be su
93. cas 9 Slightly loosen the outlet connector and remove ing the connector CAUTION Discard old seal washer replace with a new one 1 Flow control spring 2 Spool valve assembly 3 O ring 1 O ring 4 Connector 2 Straight pin 2 ea ooo 2 TURBO MODEL 4 Rotor 1 Using ST place the oil pump in a vise and re 5 Vane 10 ea move the four bolts which secure rear cover 6 Pressure plate ST 34199AE020 MOUNT 7 O ring 2 ea 7 Pry the oil seal off using a screwdriver CAUTION Be careful not to scratch inner surface of cas ing 2 Using a screwdriver pry the retaining ring off CAUTION Do not remove cam ring rotor etc 1 Oil seal 2 Screwdriver 8 Remove the pressure switch 3 Extract the oil pump pulley from the front casing PS 60 OIL PUMP POWER ASSISTED SYSTEM POWER STEERING 4 Remove the following parts from the front cas D ASSEMBLY ing 1 O ring 2 Straight pin 2 ea 3 Cam ring 4 Rotor 5 Vane 10 ea 6 Pressure plate 7 O ring 2 ea 5 Place the oil pump in a vise CAUTION Do not place oil pump directly in the vise use soft pads and hold oil pump lightly to protect the pump 6 Pry the oil seal off using a screwdriver CAUTION Be careful not to scratch inner surface of cas ing 1 NON TURBO MODEL 1 Reassembly precautions 1 Whenever the O rings oil seals and snap rings are removed they must be replaced wi
94. connector and chassis ground Connector amp terminal F49 No 4 Chassis ground CHECK POOR CONTACT IN ABSCM amp H U CONNECTOR Is the resistance less than 0 5 Go to step 3 Is there poor contact in ABSCM amp H U connector nector ABS 39 Repair the con ABS DIAGNOSTICS Repair the diagno sis terminal har ness Repair harness connector between ABSCM amp H U and diagnosis connec tor Replace the ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS D DTC 21 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH FRONT RH NOTE For the diagnostic procedure refer to DTC 27 lt Ref to ABS 41 DTC 27 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH REAR Diagnostics Chart with Diagnosis Connector gt E DTC 23 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH FRONT NOTE For the diagnostic procedure refer to DTC 27 lt Ref to ABS 41 DTC 27 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH REAR LH Diagnostics Chart with Diagnosis Connector gt F DTC 25 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH REAR RH NOTE For the diagnostic procedure refer to DTC 27 lt Ref to ABS 41 DTC 27 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH REAR LH Diagnostics Chart with Diagnosis Connec
95. damaged by bearing roller S3MO0172B A Arrow mark DI 29 REAR DIFFERENTIAL DIFFERENTIALS 5 Tighten the side bearing retainer bolts 15 Recheck the crown gear to pinion backlash CAUTION Backlash Before tightening the two side bearing retainer 0 10 0 20 0 0039 0 0079 bolts apply Lock Tite to bolt threads r Lock Tite BOND 1105 or equivalent Tightening torque 10 3 1 05 kgf m 7 6 ft Ib 16 Check the crown gear runout on its back sur face and make sure pinion and crown gear rotates smoothly Limit of runout Less than 0 05 mm 0 0020 in 6 Measure the crown gear to drive pinion backlash Set the magnet base on differential carrier Align the contact point of dial gauge with tooth face of crown gear and move crown gear while holding drive pinion still Read the value in dicated on dial gauge Backlash 0 10 0 20 mm 0 0039 0 0079 in 53 0525 17 Checking and adjusting the tooth contact of crown gear 1 Apply an even coat of red lead on both sides of three or four teeth on the the crown gear Check the contact pattern after rotating the crown gear several revolutions back and forth until a definite contact pattern appears on the crown gear 2 When the contact pattern is incorrect read 7 At the same time measure the turning resis just according to the instructions given tance of drive pinion Compared with the r
96. do the step 2 all over again 4 Start and idle the engine 5 Continue to turn the steering wheel slowly from lock to lock again until the bubbles stop appearing in the tank while keeping the fluid at that level It is normal that bubbles stop appearing after three times turning of steering wheel 6 In case bubbles do not stop appearing in the tank leave it about half an hour and then do the step 5 all over again 7 Stop the engine and take out safety stands after jacking up vehicle again Then lower the vehicle and idle the engine 8 Continue to turn the steering wheel from lock to lock until the bubbles stop appearing and change of the fluid level is within 3 mm 0 12 in 9 In case the following happens leave it about half an hour and then do step 8 again 1 The fluid level changes over 3 mm 0 12 in 2 Bubbles remain on the upper surface of the fluid 3 Grinding noise is generated from oil pump PS 72 POWER STEERING FLUID 10 Check the fluid leakage at flare nuts after turn ing steering wheel from lock to lock with engine running CAUTION e Before checking wipe off any fluid on flare nuts and piping e In case the fluid leaks from flare nut it is caused by dust or the like and or damage be tween flare and tapered seat in piping Soremove the flare nut tighten again it to the specified torque after cleaning flare and ta pered seat If flare or tapered seat is damaged replace it with a new one
97. exceeds the limit check for abnormal free play at hub bearing and runout in the thrust direction Ref to 05 22 INSPECTION Front Axle If the hub bearing is okay replace the disc rotor Disc rotor runout limit 0 075 mm 0 0030 in 3 Measure the disc rotor thickness If the thickness of disc rotor is below runout limit re place the disc rotor NOTE Make sure the micrometer is set 5 mm 0 20 in in ward of rotor outer perimeter Standard Service Disc outer value limit diameter 0 945 in 0 866 in 10 91 in Disc rotor thickness A 16 24 0 mm 22 0 mm 294 mm 0 945 in 0 866 in 11 57 in BR 18 FRONT DISC BRAKE ASSEMBLY BRAKE 4 Front Disc Brake Assembly A REMOVAL 1 Set the vehicle on the lift 2 Loosen the wheel nuts 3 Jack up the vehicle and remove the front wheel 4 Remove the union bolt and disconnect the brake hose from caliper body assembly body 6 Raise the caliper body and move it toward the vehicle center to separate it from support 7 Remove the support from housing NOTE Remove the support only when replacing it or the rotor It need not be removed when servicing the caliper body assembly 8 Clean mud and foreign particles from the caliper body assembly and support B INSTALLATION 1 Install the support on housing Tightening torque 80 N m 8 2 kgf m 59 ft lb CAUTION Always replace the pads for both the left and right whee
98. for wear Clip for damage End coupling or adapter for degradation Replace with new one CAUTION Although surface layer materials of rubber hoses have excellent weathering resistance heat resis tance and resistance for low temperature brittleness they are likely to be damaged chemically by brake fluid battery electrolyte engine oil and automatic transmission fluid and their service lives are to be very shortened It is very important to keep the hoses free from before mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids Since resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or cold conditions for the hoses and their service lives are shortening accord ingly it is necessary to perform careful inspection frequently when the vehicle is used in hot weather areas cold weather area and or a driving condition in which many steering operations are required in short time Particularly continuous work of relief valve over 5 seconds causes to reduce service lives of the hos es the oil pump the fluid etc due to over heat So avoid to keep this kind of condition when servicing as well as driving Pressure hose burst Forced out return hose Fluid bleeding out of hose slightly Excessive play of engine due to deterioration of crue engine mounting rubber Excessive holding tim
99. from rust Use specified hydraulic oil for rust prevention after cleaning and drying 6 Reverse the sequence of disassembly pro cedures 2 Apply grease to the oil seal and inner surface of front casing at bearing location CAUTION Make sure that the front body internal surfaces are free from damage 3 Attach ST to front body Using a press install the oil seal ST 34199 030 INSTALLER B4M1667A 4 Install the pump pulley to front body 5 Using ST place the oil pump in a vise ST 34199AE020 MOUNT 6 Remove the rear cover PS 64 OIL PUMP 7 Install the following parts to casing 1 O ring 2 Pressure plate 3 Rotor 4 Vane 5 Cam ring 6 Straight pin 7 O ring NOTE Install the rotor with the mark facing the rear case side 1 Mark 2 Rear 8 Using 8 mm box wrench tap the retaining ring into the shaft groove POWER ASSISTED SYSTEM POWER STEERING 9 Install the O ring to the rear cover 10 Install the rear cover Tightening torque 27 5 N m 2 8 kgf m 20 3 ft lb CAUTION Loosely tighten the bolts in the sequence A B C and D shown in figure Then tighten in the same sequence 11 When the reassembly procedures have been completed turn the shaft by hand to ensure it turns smoothly If it binds or other unusual conditions are evident disassemble again and check for foreign matter trapped on sliding surfaces and improper in stallation
100. ground NOTE For the DTC 22 and 24 Go to step 17 CHECK ABSCM amp H U Is the same diagnostic trouble Replace the to step 18 1 Connect all connectors code as in the current diagno BSCM amp H U 2 Erase the memory sis still being output cRef to ABS 7 3 Perform the inspection mode ABS Control Mod 4 Read out the diagnostic trouble code Jle and Hydraulic control Unit ABSCM amp H U gt CHECK ANY OTHER DIAGNOSTIC TROU other diagnostic trouble Proceed with the X temporary noise BLE CODES APPEARANCE codes being output diagnosis corre nterference sponding to the Jiagnostic trouble zode ABS 51 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS ABS 52 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS L DTC 29 ABNORMAL ABS SENSOR SIGNAL ANY ONE OF FOUR DIAGNOSIS Faulty ABS sensor signal noise irregular signal etc e Faulty tone wheel Wheels turning freely for a long time TROUBLE SYMPTOM ABS does not operate ABS 53 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR REAR ABS SENSOR LH SENSOR RH SENSOR RH 2122 23 74 55 1 2 3 4 5 6 7 8 9710 11112 13 14 15 16 17 18 19 20 99 OOH BR0084 ABS 54 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNO
101. in the NOTE former procedure until bushing is correctly posi Use the same ST as that used during disassembly tioned in trailing link NOTE Using the same ST as that used during dissassem bly 1 Press D c 1 7 2 4 0198 3 Lateral link 4 Flange 1 Press 2 Plunger 3 Lateral link E INSPECTION Visually check the lateral links for damage or bends RS 18 REAR CROSSMEMBER REAR SUSPENSION 7 Rear Crossmember A REMOVAL CAUTION Do not subject the ABS sensor harness to ex cessive tension Models equipped with ABS 1 Separate the front exhaust pipe and rear ex haust pipe 2 Remove the rear exhaust pipe and muffler 3 Remove the rear differential lt Ref to DI 19 REMOVAL Rear Differential gt 4 Place a transmission jack under rear crossmem ber JY 5 Remove the bolts securing crossmember to ve hicle body and remove the crossmember 6 Scribe an alignment mark on the rear lateral link cam boit and crossmember 7 Remove the front and rear lateral links by loos ening nuts B INSTALLATION 1 Install in the reverse order of removal 2 For installation and tightning torque of rear differ ential Ref to DI 20 INSTALLATION Rear Differential 3 Always tighten the rubber bushing when wheels are in full contact with the ground and vehicle is curb weight NOTE Check the wheel alignment and adjust if neces
102. mm 5 69 in RHD model 173 2 mm 6 82 in If it is not in specified value adjust it by adjusting the brake booster operating rod 8 Measure the clearance between threaded end of stop light switch and stopper If it is not in specified value adjust it by adjusting the position of stop light switch CAUTION Be careful not to rotate the stop light switch Stop light switch clearance A 0 3 mm 0 012 in 9 Apply grease to operating rod connecting pin to prevent it from wearing 10 Bleed air from the brake system Tightening torque Air bleeder screw 8 N m 0 8 kgf m 5 8 ft Ib 11 Conduct road tests to ensure brakes do not drag BR 39 BRAKE BOOSTER BRAKE C INSPECTION 1 OPERATION CHECK WITHOUT GAUG ES CAUTION When checking operation be sure to securely apply the hand brake Checking without gauges This method cannot determine the exact portion which has failed but it can provide a rough under standing of the nature of the failure if checking is conducted in accordance with the following proce dures Air tightness check Start the engine and run it for 1 to 2 minutes then turn it off Depress the brake pedal several times applying the same pedal force as that used in ordi nary braking operations The pedal stroke should be greatest on the 1st depression and it should be come smaller with each successive depression If no change occurs in the pedal height while in a de
103. monitor signal ABS operation signal from ABS con trol module to TCM AG ABS SEQUENCE CONTROL screen Perform ABS sequence lt Ref to ABS ABS control by operating valve 11 ABS sequence and pump motor sequen Sequence Con control tially trol gt ABS 93 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS AH FREEZE FRAME DATA NOTE Data stored at the time of trouble occurrence is shown on display e Each time trouble occurs the latest information is stored in the freeze frame data in memory Freeze frame data will be memorized maximum to three f freeze frame data is not properly stored memory due to a drop in ABSCM power supply etc a diagnostic trouble code DTC preceded by a question mark appears on the select monitor display This shows it may be an unreliable read ing Display screen Contents to be monitored Wheel speed detected by the Front Right FR wheel speed ABS sensor is displayed in km h or mile h Wheel speed detected by the Front Left FL wheel speed ABS sensor is displayed in km h or mile Wheel speed detected by the Rear Right R wheel speed ABS sensor is displayed in km h or mile Wheel speed detected by the Rear Left RL wheel speed ABS sensor is displayed in km h or mile h ABSCM power _ Power involts supplied to ABSCM amp H U voltage appears on the select monitor di
104. not hit cap at the bottom of tie rod end with hammer 54 0379 1 Castle nut 2 Tie rod end 3 Knuckle arm 6 Install the front stabilizer to vehicle 7 Install the front exhaust pipe assembly 8 Install the sub frame lt Ref to FS 16 INSTALLA TION Sub Frame gt PS 27 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 9 Align the center of roll connector lt Ref to AB 17 ADJUSTMENT Roll Connector gt CAUTION Ensure that front wheels are set in straight for ward direction 10 Install the steering wheel lt Ref to PS 19 IN STALLATION Steering Wheel gt 11 Install the tires 12 Tighten the wheel nuts to the specified torque Tightening torque 90 9 1 kgf m 66 ft lb 13 Connect the ground terminal to battery 14 Pour the fluid into the oil tank and bleed air lt Ref to PS 72 Power Steering Fluid gt 15 Check for fluid leaks 16 Install the jack up plate 17 Lower the vehicle 18 Check the fluid level in oil tank 19 After adjusting toe in and steering angle tight en the lock nut on tie rod end Tightening torque 83 8 5 kgf m 61 5 ft lb CAUTION When adjusting toe in hold the boot as shown to prevent it from being rotated or twisted If twisted straighten it C DISASSEMBLY NOTE Parts requiring replacement are described in the smallest unit of spare parts including damaged parts and spare parts damaged In actual disas sembly
105. nut seating surface of the wheel are free from oils 5 If a wheel is removed for replacement or for re pair of a puncture retighten the wheel nuts to the specified torque after running 1 000 km 600 miles C INSPECTION 1 Deformation or damage on the rim can cause air leakage Check the rim flange for deformation crack or damage and repair or replace as neces sary 2 Jack up the vehicle until wheels clear the floor 3 Slowly rotate the wheel to check rim runout us ing a dial gauge Axial runout limit Radial runout limit 1 5 mm 0 059 in N 2 a 4 If the rim runout exceeds specifications remove the tire from rim and check runout while attaching dial gauge to positions shown in figure 5 If the measured runout still exceeds specifica tions replace the wheel WT 5 ALUMINUM WHEEL WHEEL AND TIRE SYSTEM 4 Aluminum Wheel A REMOVAL Refer to Steel Wheel for removal procedure of alu minum wheels lt Ref to WT 5 REMOVAL Steel Wheel gt B INSTALLATION Refer to Steel Wheel for installation procedure of aluminum wheels lt Ref to WT 5 INSTALLATION Steel Wheel gt C INSPECTION Refer to Steel Wheel for inspection procedure of aluminum wheels lt Ref to WT 5 INSPECTION Steel Wheel gt Rim runout Axial runout limit Radial runout limit 1 0 mm 0 039 in D CAUTION Aluminum wheels are easily scratched To main tain t
106. of 2 3 4 5 and 6 FS 16 FRONT TRANSVERSE LINK pR AAEE 4 Front Transverse Link A REMOVAL 1 Set the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Lift up the vehicle and remove the wheel 4 Remove the sub frame lt Ref to FS 16 RE MOVAL Sub Frame gt 5 Disconnect the stabilizer link from transverse link 6 Remove the bolt securing the ball joint of trans verse link to housing 54 0090 7 Remove the nut do not remove bolt securing the transverse link to crossmember 8 Remove the two bolts securing the bushing bracket of transverse link to vehicle body at rear bushing location 9 Extract the ball joint from housing 10 Remove the bolt securing the transverse link to crossmember and extract the transverse link from crossmember FRONT SUSPENSION B INSTALLATION 1 Temporarily tighten the two bolts used to secure the rear bushing of the transverse link to body NOTE These bolts should be tightened to such an extent that they can still move back and forth in the oblong shaped hole in the bracket which holds the bush ing 2 Install the bolts used to connect the transverse link to crossmember and temporarily tighten with nut CAUTION Discard the loosened self locking nut and re place with a new one 3 Insert the ball joint into housing 4 Connect the stabilizer link to transverse link and tempor
107. of boot CAUTION Use a new band 20 Pinch the end of band with pliers Hold the clip and tighten securely NOTE When tightening boot exercise care so that the air within the boot is appropriate 21 Tighten the band by using ST ST 925091000 BAND TIGHTENING TOOL NOTE Tighten the band until it cannot be moved by hand 22 Tap on the clip with the punch provided at the end of ST ST 925091000 CAUTION Tap to an extent that the boot underneath is not damaged BAND TIGHTENING TOOL 23 Cut off band with an allowance of about 10 mm 0 39 in left from the clip and bend this allowance over the clip CAUTION Be careful so that the end of the band is in close contact with clip 24 Fix up boot on the EBJ the same manner NOTE Extend and retract the SFJ to provide equal grease coating E INSPECTION Check the removed parts for damage wear corro sion etc If faulty repair or replace 1 SFJ Shudder less Freering tripod Joint Check seizure corrosion damage and excessive pay 2 2 Shaft Check excessive bending twisting damage and wear 3 EBJ Bell Joint Check seizure corrosion damage and excessive play 4 Boot Check for wear warping breakage or scratches 5 Grease Check for discoloration or fluidity DS 37 FRONT DRIVE SHAFT BOOTS DRIVE SHAFT SYSTEM 6 Front Drive Shaft Boots A INSPECTION Inspect the wear warping breakage or scratches for boot If faulty
108. of pedal pad Pedal height L 148 mm 5 83 in Brake pedal free play A 1 3 0 04 0 12 in Depress brake pedal pad with a force of less than 10 N 1 kof 2 Ib 4 0366 1 Stop light switch 2 Mat 3 Toe board 4 Brake booster operating rod 3 If it is not in specified value adjust it by adjusting the brake booster operating rod length BR 54 STOP LIGHT SWITCH BRAKE 19 Stop Light Switch A REMOVAL 1 Disconnect the ground terminal from battery 2 Disconnect the stop light switch connector 3 Loosen the nuts and unscrew stop light switch to remove B4M1753D 1 Stop light switch B INSTALLATION 1 Screw the stop light switch onto a bracket and secure it temporarily with a nut 2 Adjust the stop light switch position and then tighten the nut lt Ref to BR 56 ADJUSTMENT Stop Light Switch gt Tightening torque 8 N m 0 8 kgf m 5 8 ft Ib B4M1753E C INSPECTION 1 If the stop light switch does not operate properly or if it does not stop at the specified position re place with a new one Specified position L 2mm 0 079 in G4M0327 2 Measure the clearance between threaded end of stop light switch and stopper CAUTION Be careful not to rotate the stop light switch Stop light switch clearance A 0 3 mm 0 012 in B4M0617E 1 Stop light switch 2 Stopper 3 Brake pedal 3 If it is not in specified value adjust it by adj
109. of specified grease into the interior of DOJ outer race 7 Apply a coat of specified grease to the cage pocket and six balls 8 Insert six balls into the cage pocket 9 Align the outer race track and ball positions and place in the part where shaft inner race cage and balls are previously installed and then fit outer race 4 0227 A Outer Grease 05 42 REAR DRIVE SHAFT DRIVE SHAFT SYSTEM 10 Install the circlip in the groove on the DOJ outer race NOTE Assure that the balls cage and inner race are completely fitted in the outer race of DOJ Exercise care not to place the matched position of circlip in the ball groove of outer race e Pull the shaft lightly and assure that the circlip is completely fitted in the groove 11 Apply an even coat of the specified grease 20 to 30 0 0 71 to 1 06 oz to the entire inner surface of boot Also apply grease to shaft 12 Install the DOJ boot taking care not to twist it NOTE The inside of the larger end of DOJ boot and the boot groove shall be cleaned so as to be free from grease and other substances When installing DOJ boot position outer race of DOJ at center of its travel 13 Put a band through the clip and wind twice in alignment with band groove of boot CAUTION Use a new band 14 Pinch the end of band with pliers Hold the clip and tighten securely NOTE When tightening boot exercise care so t
110. packing to be caught when installing valve assembly 16 Tighten the bolts alternately to secure the valve assembly Tightening torque 25 N m 2 5 kgf m 18 1 ft lb CAUTION Be sure to alternately tighten boits 17 Apply grease to the sleeve insertion hole 18 Apply grease to the dust seal insertion hole CAUTION Apply clean grease with clean hands If material having a sharp edge is used for applying grease oil seal at the inside might be damaged 19 Apply grease to the sliding surface of sleeve and spring seat then insert the sleeve into the pin ion housing Fit the spring into the sleeve the screw pack grease inside of screw then install the screw B4M1129B 1 Adjusting screw 2 Spring 3 Sleeve 20 Rack and pinion backlash adjustment 1 Loosen the adjusting screw 2 Rotate the input shaft so that the rack is in the straight ahead direction 3 Apply grease to the sleeve B4M1130B 1 Adjusting screw 2 Lock nut 3 Spring 4 Sleeve 4 Tighten the adjusting screw by two threads LILE 5 Apply liquid packing to at least 1 3 of entire perimeter of adjusting screw thread G4M0121 Liquid packing THREE BOND 1141 S4M0385A 1 Apply liquid packing to at least 1 3 of entire perimeter 6 Tighten the adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft lb and back off 25 PS 40 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 7 Install t
111. part that has been dropped accidentally 2 ASSEMBLING PROCEDURE 1 Assembling piston assembly Apply recommended brake fluid to inside wall of cylinder and to outer surface of piston assembly and install the piston assemblies carefully into inder 2 Assembling cylinder pin 3 Press the pawi and install the piston retainer into the master cylinder 1 54 0124 4 install the seal to reservoir tank 1 Seal 5 Install the pin with drift pins which secures the reservoir tank to master cylinder E INSPECTION If any damage deformation wear swelling rust and other faults are found on the primary piston as sembly secondary piston assembly supply valve stopper or gasket replace the faulty part CAUTION The primary and secondary pistons must be replaced as complete assemblies The service limit of the clearance between each piston and the master cylinder inner dia is 0 11 mm 0 0043 in When handling parts be extremely careful not to damage or scratch the parts or let any foreign matter get on them BR 37 BRAKE BOOSTER BRAKE 12 Brake Booster A REMOVAL 1 Remove or disconnect the following parts at en gine compartment 1 Disconnect the connector for brake fluid lev el indicator 2 Remove the brake pipes from master cylin der 3 Remove the master cylinder installing nuts 4 Disconnect the vacuum hose from brake booster 2 Remove the following par
112. portion at end of rack shaft Move rack shaft to stroke end two 2 or three 3 times to squeeze grease which accumulates on both ends Remove grease to prevent it from choking air passage hole 4 Apply grease to the sleeve insertion hole 5 Apply grease to the dust seal insertion hole CAUTION Apply clean grease with clean hands If material having a sharp edge is used for applying grease oil seal at the inside might be damaged 6 Fixing rack housing Fix the rack housing in vice using ST ST 926200000 STAND CAUTION e When fixing rack housing in vice be sure to use this special tool Do not fix rack housing in vice using pad such as aluminum plates etc When using old rack housing be sure to clean and remove rust before assembling Check pinion housing bushing carefully 7 Install the oil seal to rack 8 Fit ST over toothed portion of rack assembly and check for binding or unsmooth insertion If any deformation is noted on flats at the end of rack shape by using file and wash with cleaning fluid ST 926390001 COVER amp REMOVER 54 0406 1 55 9 Apply genuine grease to the teeth of thoroughly washed rack assembly and fit ST over the toothed portion CAUTION e Be careful not to block air passage with grease Remove excessive grease e After fitting cover check air passage hole for clogging If clogged open by removing grease from the hole e Check rack shaft for damage
113. rear differential member 2 Check bushings of rear differential member for cracking hardening or damage If cracking hardening or damage is excessive re place rear differential member DI 40 GENERAL DIAGNOSTIC TABLE DIFFERENTIALS 8 General Diagnostic Table A INSPECTION Symptom or trouble 1 Oil leakage 1 Worn scratched or incorrectly seated Repair or replace front or side oil seal Scored battered or excessively worn sliding surface of com panion flange 2 Clogged or damaged air breather Clean repair or replace 3 Loose bolts on differential spindle or Tighten bolts to specified torque Replace side retainer or incorrectly fitted O ring O ring 4 Loose rear cover attaching bolts or Tighten bolts to specified torque Replace damaged gasket gasket and apply liquid packing 5 Loose oil filler or drain plug Retighten and apply liquid packing 6 Wear damage or incorrectly fitting for Repair or replace spindle side retainer and oil seal 2 Seizure 1 Insufficient backlash for hypoid gear Readjust or replace NOTE 2 Excessive preload for side rear or Readjust or replace Seized or damaged parts should be re front bearing 3 insufficient or improper oil used placed and also other parts should be Replace seized part and fill with specified oil to specified level thoroughly checked for any defect and should be repaired or replaced as re quired
114. relay and chassis connector and chassis ground ground Connector amp terminal B264 No 3 Chassis ground CHECK ABS RELAY 1 Connect the battery to ABS relay terminal No 1 and 3 2 Measure the resistance between ABS relay terminals CHECK INPUT VOLTAGE OF ABSCM amp H U 1 Disconnect the connector from ABSCM amp H U 2 Run the engine at idle 3 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 1 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U 7 1 Turm the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 23 Chassis ground Is the resistance less than 5 Q Is the resistance less than 10 Q Replace the ABS relay Is the voltage between 10 and 17 V Go to step 10 Repair harness connector between battery ignition switch and ABSCM amp H U Is the resistance less than 0 5 Q Go to step 11 Repair the ABSCM amp H U ground harness ABS 135 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK POOR CONTACT IN CONNECTORS CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Is there p
115. repair or replace B REPLACEMENT 1 Disconnect the ground terminal from battery 2 Jack up the vehicle support it with safety stands rigid racks and remove the front wheel cap and wheels NOTE Do not remove the axie nut 3 Remove the stabilizer link 4 Disconnect the transverse link from the housing 5 Remove the spring pin which secures transmis sion spindle to the SFJ CAUTION Use a new spring pin 6 Remove the EBJ and SFJ boots from the drive shaft Ref to 05 33 DISASSEMBLY Front Drive Shaft 7 Install the EBJ and SFJ boots to the drive shaft Ref to 05 35 ASSEMBLY Front Drive Shaft 8 Install the SFJ on transmission spindle and drive spring pin into the place CAUTION Always use a new spring pin 9 Connect the transverse link to the housing 10 Install the stabilizer link DS 38 REAR DRIVE SHAFT DRIVE SHAFT SYSTEM 7 Rear Drive Shaft 5 Remove the axle nut and drive shaft If it is hard to remove use ST1 and ST2 A REMOVAL ST1 926470000 AXLE SHAFT PULLER 1 Disconnect the ground cable from battery ST2 927140000 AXLE SHAFT PULLER 2 Lift up the vehicle and remove the rear wheel PLATE cap and wheels CAUTION CAUTION Be careful not to damage tone wheel when re Be sure to loosen and retighten axle nut after moving rear drive shaft removing wheel from vehicle Failure to follow this rule may damage wheel bearings 3 Unlock the axle nut 4 Remove the D
116. ring in its groove CAUTION Make sure to install it firmly to groove 6 Using ST1 and ST2 press the outer oil seal until it contacts the bottom of housing ST1 927410000 SEAL INSTALLER ST2 927400000 HOUSING STAND CAUTION Do not apply pressure more than 3 92 kN 0 4 ton 0 4 US ton 0 4 Imp ton 7 Using ST1 and ST2 press the inner oil seal until it contacts circlip ST1 927410000 OIL SEAL INSTALLER ST2 927400000 HOUSING STAND CAUTION Do not apply pressure more than 3 92 0 4 ton 0 4 US ton 0 4 Imp ton 8 Invert the ST and housing ST 927400000 HOUSING STAND DS 21 DRIVE SHAFT SYSTEM 9 Apply the sufficient grease to seal lip Specified grease SHELL 6459N CAUTION e f specified grease is not available remove bearing grease and apply Auto Rex A instead Do not mix different types of grease 10 Install the disc cover to housing the three bolts Tightening torque 18 N m 1 8 kgf m 13 0 ft lb 11 Attach the hub to ST1 securely 12 Clean the dust or foreign particles from the pol ished surface of hub 13 Using ST2 press the bearing into hub by driv ing inner race ST1 927080000 STAND ST2 927120000 INSTALLER CAUTION Do not apply pressure more than 25 KN 2 5 ton 2 3 US ton 2 5 Imp ton E INSPECTION 1 Inspect the rattle of bearing give the tires a shake with grasping both the upper and lower side
117. rod Apply this too to rack 4 2411 925711000 PRESSURE Used for measuring oil pump pressure GAUGE amp 49 lt 4 2412 926200000 STAND Used when inspecting characteristic of gearbox assembly and disassembling it B4M2413 34099AC010 ADAPTER HOSE A Used with PRESSURE GAUGE 925711000 B4M2414 PS 11 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34099FA100 STAND BASE Used for assembling power steering gearbox For LHD model G1H0273 34099 020 ADAPTER HOSE B Used with PRESSURE GAUGE 925711000 B4M2415 926230000 SPANNER For the lock nut when adjusting backlash of gearbox 4 4 2416 34099 100 SPANNER 510047 5 12 Measurement of rotating resistance of gear box assembly GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING ILLUSTRATION TOOL NUMBER DESCRIPTION 34199AE020 MOUNT e Used for disassembling oil pump For TURBO model B4M2417 34199AE030 INSTALLER Used for installing oi seal into oil pump B4M2418 OIL CHARGE 34199AE040 GUIDE 4 2419 927640000 INSTALLER B Used for charging power steering oil Used for installing ball bearing into housing B4M2420 PS 13 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 926370000 INSTALLER A e Used for installing valve
118. rod end with hammer Cotter pin B Castle nut C Tie rod DS 18 FRONT AXLE DRIVE SHAFT SYSTEM 9 While depressing brake pedal tighten the axle DISASSEMBLY nut and lock it securely 1 Using ST1 support housing and hub securely Tightening torque 2 Attach ST2 to housing and drive hub out 186 19 kgf m 137 ft lb ST1 927060000 HUB REMOVER CAUTION ST2 927080000 STAND e Use a new axle nut e Always tighten axle nut before installing wheel on vehicle If wheel is installed and comes in contact with ground when axle nut is loose wheel bearings may be damaged e Be sure to tighten axle nut to specified torque Do not overtighten it as this may dam age wheel bearing 10 After tightening the axle nut lock it securely 11 Install the wheel and tighten the wheel nuts to specified torque If inner bearing race remains in the hub remove it Tightening torque with a suitable tool commercially available 90 N m 9 2 kgf m 66 5 ft Ib CAUTION e Be careful not to scratch polished area of hub e Be sure to install inner race on the side of outer race from which it was removed DS 19 FRONT AXLE DRIVE SHAFT SYSTEM 3 Remove the disc cover from the housing 8 Using ST and a hydraulic press drive hub bolts out ST 927080000 STAND CAUTION Be careful not to hammer the hub bolts This may deform hub 4 Using a standard screwdriver re
119. rubber seat and spring seat NOTE Ensure the upper spring seat is positioned as shown in the figure 1 Outside of body S4M0097B 8 Install the strut mount to the piston rod and tight en the self locking nut temporarily CAUTION Be sure to use a new self locking nut 9 Using a hexagon wrench to prevent strut rod from turning tighten self locking nut with ST ST 927760000 STRUT MOUNT SOCKET Tightening torque 55 5 6 kgf m 41 ft lb 54 0096 5 22 FRONT STRUT FRONT SUSPENSION 10 Loosen the coil spring carefully E INSPECTION Check the disassembled parts for cracks damage and wear and replace with new parts if defective 1 DAMPER STRUT 1 Check for oil leakage 2 Move the piston rod up and down to check that it operates smoothly without any binding 3 Play of piston rod e Measure the play as follows Fix the outer shell and fully extend the rod Set a dial gauge at the end of the rod L 10 mm 0 39 then apply a force of W 20 2 kgf 4 Ib to threaded portion With the force of 20 N 2 4 Ib applied read the dial gauge indication P4 Apply a force of 20 2 kof 4 Ib in the opposite direction of W then read the dial gauge indication Po The free play is determined by the following equa tion Play P Limit of play Less than 0 8 mm 0 031 in If the play is greater replace the strut 2 STRUT MOUNT Check the rub
120. sensor Front Ref to ABS 14 Front ABS Sen Sor Hear Hef to ABS 18 Rear ABS Sensor Is the voltage less than 1 V UH EN EC IUS GNE LE E VON rmt 797 MET TRISTE EUR MERIT E E NEUE REMO ar ABSCM amp H U AND ABS SENSOR 1 Turn the ignition switch to OFF 2 Connect the connector to ABS sensor 3 Measure the resistance between ABSCM amp H U connector terminals Connector amp terminal 21 F49 No 11 No 12 DTC 23 F49 No 9 No 10 25 F49 14 No 15 DTC 27 F49 No 7 8 CHECK BATTERY SHORT OF HARNESS Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal DTC 21 F49 11 Chassis ground DTC 23 F49 No 9 Chassis ground DTC 25 F49 No 14 Chassis ground DTC 27 F49 No 7 Chassis ground CHECK BATTERY SHORT OF HARNESS 1 Turn the ignition switch to ON 2 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal DTC 21 F49 No 11 Chassis ground DTC 23 F49 No 9 Chassis ground DTC 25 F49 No 14 Chassis ground DTC 27 F49 No 7 Chassis ground CHECK INSTALLATION OF ABS SENSOR Tightening torque 32 3 3 kgf m 24 ft Ib Rear LH No 1
121. side gear thrust washer 3 Check the condition of rotation after apply ing oil to the gear tooth surfaces and thrust sur faces 4 After inserting the pinion shaft lock pin into differential case stake the both sides of the hole to prevent pin from falling off 12 Install the crown gear on differential case CAUTION Before installing bolts apply Lock Tite to boit threads Lock Tite THREE BOND 1324 or equivalent NOTE Tighten diagonally while tapping the bolt heads Tightening torque 103 10 5 kgf m 76 ft lb 13 Press the side bearing cone onto differential case with ST ST 398487700 DRIFT G3M0091 14 Adjusting the side bearing retainer shims 1 The driven gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness 2 Install the differential case assembly into dif ferential carrier in the reverse order of disas sembly 3 Install the side retainer shims and O rings to the left and right retainers from which they were removed NOTE e Replace the broken or cracked O ring with a new one Replace the broken or corroded side retainer shim with a new one of same thickness Side bearing retainer shim Part No Thickness mm in 383475201 0 20 0 0079 4 Align the arrow mark on differential carrier with that marked on side retainer during installa tion CAUTION Be careful that side bearing outer race is not
122. splines with vinyl tape to prevent boot from scratches 10 Remove the SFJ boot DS 34 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM ASSEMBLY CAUTION Use specified grease EBJ side NTG2218 Part No 28093AA000 SFJ side SSG6003 Part No 28093TA000 1 Place the EBJ boot and small boot band on the BJ side of shaft CAUTION Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches 2 Place the drive shaft in a vise CAUTION Do not place drive shaft directly in the vise use wooden blocks 3 Apply a coat of specified grease 60 to 70 g 2 12 to 2 47 oz to EBJ 4 Apply an even coat of specified grease 20 to 30 9 0 71 to 1 06 oz to the entire inner surface of boot Also apply the grease to the shaft NOTE The inside of the larger end of BJ boot and the boot groove shall be cleaned so as to be free from grease and other substances 5 Install the boot projecting portion to the EBJ groove B4M2217B A EBJ B Lorge boot band C Boot 6 Set the large boot band in place 7 Install the boot projecting portion to shaft groove B C ames 111 i 4 1297 Boot Small boot band C Shaft DS 35 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM 8 Tighten the boot bands using ST torque wrench and socket flex handle ST 28099 000 BOOT BAND PLIER A Large boot band B Boot C Torque wrench D Socket flex handle E BJ
123. the DOJ spline end into the bore of side oil seal and remove ST CAUTION Do not allow DOJ splines to damage side seal ST 28099PA090 SIDE OIL SEAL PROTEC TOR 12 Align the DOJ and differential splines 13 Push the housing to insert DOJ into the differ ential NOTE Make sure the DOJ is inserted properly CAUTION Discard old self locking nut Replace with a new one DS 45 GENERAL DIAGNOSTIC TABLE DRIVE SHAFT SYSTEM 9 General Diagnostic Table A INSPECTION NOTE Vibration while cruising may be caused by an unbalanced tire improper tire inflation pressure improper wheel alignment etc Symptom Remedy 1 Vibration of propeller shaft 1 Worn or damaged universal joint Replace NOTE 2 Unbalanced propeller shaft due to Replace Vibration is caused by propeller shaft dur bend or dent Ing operation and is transferred to vehicle F3 installation of propeller shaft Retighten body Generally vibration increase in pro damaged center mounting rubber 1 2 portion to vehicle speed 1 Worn or damaged universal joint Replace 2 Tapping when starting and noise while cruising caused by propeller shaft Replace Retighten Replace damaged center mounting rubber Repair or replace Repair or replace DS 46 5 1 2 3 4 5 6 7 8
124. the Go to step 7 ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Proceed with the diagnosis corre sponding to the diagnostic trouble code 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output temporary poor contact ABS 163 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ABS 164 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS AE DTC 56 OPEN OR SHORT CIRCUIT IN G SENSOR CIRCUIT DIAGNOSIS e Faulty G sensor output voltage TROUBLE SYMPTOM ABS does not operate ABS 165 B29 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM 9 TEE 5161718 ABS CONTROL MODULE HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR E t t 1 ejeje f gt 200 4 mi ABS G SENSOR 1121314 15 6 7 8 9 10111112113 14 15 16117 1819120 Qu 0090 5 166 EPI n DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Ye Ne Repair the con Go to step 3 nector Replace the Go to step 4 ABSCM amp H U lt Ref to ABS 7 ABS C
125. the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 23 Chassis ground CHECK POOR CONTACT IN CONNECTORS s the voltage more than 10 V to step 5 Go to step 6 Go to step 7 s the resistance less than 5 2 s the resistance less than 10 2 s the voltage between 10 and 5 V the resistance less than 0 5 2 s there poor contact in con vectors between generator jattery and ABSCM amp H U CHECK ABSCM amp H U s the same diagnostic trouble 1 Connect all connectors zode as in the current diagno 2 Erase the memory 16 still being output 3 Perform the inspection mode 4 Read out the diagnostic trouble code Repair the con nector Replace the ABSCM amp H U Ref to ABS 7 ABS Control Mod Control Unit ABSCM amp H U ABS 63 Go to step 8 Go to step 9 Repair the ABSCM amp H U ground harness ule and Hydraulic n harness battery and Relay holder zonnector Repair open circuit n harness oetween battery and Relay holder connector Repair harness connector oetween battery ignition switch and ABS relay Repair open circuit between ABS relay and chassis ground Replace the ABS relay Repair harness connector
126. tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or safety stands at the specified points Apply gear oil onto sliding or revolution surfaces before installation Before installing O rings or snap rings apply suf ficient amount of gear oil to avoid damage and de formation Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice Avoid damaging the mating face of the case DI 7 GENERAL DESCRIPTION DIFFERENTIALS D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 9 398477701 HANDLE Used for installing front and rear bearing cone B3M1893 398477702 DRIFT Used for press fitting the bearing cone of differ ential carrier rear B3M1894 398217700 ATTACHMENT SET Stand for rear differential carrier disassembly and assembly B3M1895 498447120 DRIFT Used for installing front oii seal B3M1896 DI 8 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION 498427200 FLANGE WRENCH Used for stopping rotation of companion flange when loosening and tightening self lock nut B3M1897 398467700 DRIFT Used for removing pinion pilot bearing and front bearing cone B3M1898 399780104 WEIGHT Used for installing front bearing cone pilot bear ing companion flange B3M1899 899580100 INSTALLER
127. to step 14 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary poor contact ABS 92 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS AB SELECT MONITOR Applicable cartridge of select monitor lt Ref to ABS 10 SPECIAL TOOLS PREPARATION TOOL General Description gt NOTE For basic handling of the select monitor refer to its Operation Manual AC DIAGNOSTIC TROUBLE CODES DTC ARE DISPLAYED A maximum of 3 diagnostic trouble codes DTC are displayed in order of occurrence e f a particular diagnostic trouble code DTC is not properly stored in memory due to a drop SCM amp H U power supply etc when a problem oc curs the diagnostic trouble code DTC followed by a question mark appears on the select mon itor display This shows it may be an unreliable reading 21 Front Right ABS Sensor Circuit Open or Shorted Battery a 11 54 0076 e a refers to the troubles in order of occurrence Latest Old Older and Reference Display screen Contents to be monitored The most recent diagnostic trouble code Latest DTC appears on the select monitor dis play second most recent diagnostic trou ble code DTC appears on the select AD CLEAR MEMORY monitor display Display screen Contents to be monitored The third most recent diagnostic t
128. torque 32 3 3 kgf m 24 ft lb 8 Apply grease to the adjusting screw and both ends of adjuster Brake grease Dow Corning Molykote No 7439 Part No 725191460 54 0457 9 Install the brake shoe lt Ref to BR 31 INSTAL LATION Rear Drum Brake Shoe gt 10 Install brake drum lt Ref to BR 32 INSTALLA TION Rear Drum Brake Drum gt 11 After installing brake assembly bleed air from brake line lt Ref to BR 46 Air Bleeding gt C DISASSEMBLY 1 Remove the right and left dust boots from wheel cylinder 1 Bleeder cap 2 Bleeder screw 3 Spring 4 Cylinder 5 Cup 6 Piston 7 Boot 2 Remove the piston cup spring and air bleeder screw and cap BR 34 REAR DRUM BRAKE ASSEMBLY BRAKE D ASSEMBLY 1 Clean all parts with brake fluid Check and re place faulty parts Cup and boot for damage or fatigue Cylinder piston and spring or damage or rust for mation 2 Assembly is the reverse order of disassembly 1 When installing the cup use ST apply brake fluid to the frictional surface for smooth in stallation and pay attention to cup direction 2 STs are available in different sizes CAUTION When replacing the repair kit make sure that the sizes of cylinder and cup are the same as those which were replaced Use only the tool of the correct size ST ADAPTER Applicable size Panno 19 0 mm 3 4 in 926460000 CAUTION While as
129. universal joint free play 0 mm 0 in Max value of universal joint swinging torque 0 3 N m 0 03 kgf m 0 2 ft Ib Measurement of folding torque of universal joint is Service limit as shown in the figures Maximum load 7 3 N 0 74 kgf 1 64 Ib or less Service limit Maximum load 7 3 N 0 74 kgf 1 64 Ib or less 54 0445 1 Yoke Steering column side S4M0443A Service limit 1 Yoke gearbox side Maximum load 7 3 0 74 kgf 1 64 Ib or less Service limit Maximum load 7 3 0 74 kgf 1 64 Ib or less 54 0446 1 Yoke Steering column side S4M0444A 1 Yoke gearbox side 5 22 TILT STEERING COLUMN 4 Tilt Steering Column A REMOVAL POWER ASSISTED SYSTEM POWER STEERING 1 Tilt steering column 2 Universal joint 1 Set the vehicle on the lift 2 Disconnect the battery ground terminal 3 Remove the airbag module Ref to AB 12 RE MOVAL Driver s Airbag Module WARNING Always refer to Air Bag System before per forming airbag module service Ref to AB 12 CAUTION Driver s Airbag Module 4 Remove the steering wheel Ref to PS 19 RE MOVAL Steering Wheel 5 0023 Tightening torque kgf m ft lb 1 24 2 4 17 4 T2 25 2 5 18 1 5 Remove the universal joint lt Ref to PS 20 RE MOVAL Universal Joint gt 6 Remove the trim panel under instrument panel PS 23 TILT STEERING COLUMN POWER ASSISTED SYS
130. wheel steering angle is within specifications 5 REAR WHEEL TOE IN Inspection 1 Using a toe in gauge measure the rear wheel toe in Toe in 1 2 mm 0 039 0 079 in 2 Mark the rear sides of left and right tires at height corresponding to the center of spindles and mea sure distance A between marks 3 Move the vehicle forward so the that marks line up with front sides at height corresponding to the center of spindles 4 Measure the distance B between left and right marks Toe in can then be obtained by the follow ing equation A B Toe in H4M1279B e Adjustment 1 Loosen the self locking nut on inner side of link rear CAUTION When loosening or tightening the adjusting bolt hold the bolt head and turn self locking nut Discard the loosened self locking nut and re place with a new one 54 0349 1 Adjusting bolt 2 Link rear 2 Turn the adjusting bolt head until toe in is at the specification FS 12 WHEEL ALIGNMENT FRONT SUSPENSION NOTE When the left and right wheels are adjusted for toe in at the same time the movement of one scale gradu ation changes toe in by approximately 1 5 mm 0 12 in Left side Toe in is increased is decreased wise 4 0352 3 Tighten the self locking nut Tightening torque 100 10 2 kgf m 74 ft lb 6 STEERING ANGLE Inspection 1 Place the vehicle on a turning radius gauge 2
131. 0 Rear wheel If spacers cannot 0 7 1 2 mm 0 028 0 047 in correct the gap re place the wom sensor or worn tone wheel 7 PREPARE OSCILLOSCOPE Is an oscilloscope available to step 8 ABS 119 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS vex Ye Ne i 8 CHECK ABS SENSOR SIGNAL Is oscilloscope pattern smooth Go to step 12 Go to step 9 1 Raise all four wheels of ground as shown in the figure 2 Turn the ignition switch OFF 3 Connect the oscilloscope to the connector B99 F95 or F94 in accordance with trou ble code 4 Turn the ignition switch ON 5 Rotate the wheels and measure voltage at specified frequency Ref to ABS 17 WAVE FORM Control Module Signal NOTE When this inspection is completed the AB SCM amp H U sometimes stores the DTC 29 Connector amp terminal Front RH F95 No 1 No 2 Front LH F94 No 1 No 2 Rear RH B99 No 9 10 Hear LH B99 No 4 No 5 CHECK CONTAMINATION OF ABS SENSOR 15 the ABS sensor piece or the OR TONE WHEEL tone wheel contaminated by Remove the disc rotor from hub dirt or other foreign matter Thoroughly Go to step 10 remove dirt or other foreign mat ter Replace the ABS Go to step 11 sensor or tone wheel Front Ref to ABS 14 Front ABS Sensor Rear Ref to ABS 18 Rear ABS
132. 0 V 30 to step 14 Repair open circuit n harness yetween battery ind Relay holder zonnector ER 1 Turn the ignition switch to OFF 2 Remove the fuse 3 Measure the voltage between ABS relay connector and chassis ground Connector amp terminal B225 No 5 Chassis ground 14 CHECK RELAY HOLDER 5 the fuse blown out ieplace the fuse CHECK IN OLTAGE OF ABS RE the voltage more than 10 V 3o to step 16 Repair open circuit 1 Install the fuse n harness 2 Remove the ABS relay yetween battery 3 Turn the ignition switch to ON Relay holder 4 Measure the voltage between ABS relay onnector connector and chassis ground Connector amp terminal B264 No 2 Chassis ground CHECK INPUT VOLTAGE OF ABS RELAY 5 the voltage more than 10 V to step 17 Repair harness Measure the voltage between ABS relay con onnector nector and chassis ground yetween battery Connector amp terminal gnition switch and B264 No 1 Chassis ground ABS relay 30 to step 18 Repair open circuit yetween ABS and chassis jround _ CHECK GROUND CIRCUIT OF ABS RELAY s the resistance less 5 Q 1 Turn the ignition switch to OFF 2 Measure the resistance between ABS relay connector and chassis ground Connector amp terminal B264 No 3 Chassis ground ABS 98 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK ABS
133. 1 Even if the location of the leak can be easily found by observing the leaking condition it is nec essary to thoroughly remove the oil from the sus pected portion and turn the steering wheel from lock to lock about 30 to 40 times with engine run ning then make comparison of the suspected por tion between immediately after and several hours after this operation 5 Input shaft 6 Valve housing 2 Inspect leakage from a The oil seal is damaged Replace the valve assem bly with a new one 3 Inspect leakage from b The torsion bar O ring is damaged Replace the valve assembly with a new one 4 Inspect leakage from c The oil seal is damaged Replace the valve assem bly or oil seal with a new one 5 Inspect leakage from d The pipe is damaged Replace the faulty pipe or O ring PS 45 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 6 If leak is other than a b c or d and if oil is leak ing from the gearbox move the right and left boots toward tie rod end side respectively with the gear box mounted to the vehicle and remove oil from the surrounding portions Then turn the steering wheel from lock to lock 30 to 40 times with the en gine running then make comparison of the leaked portion immediately after and several hours after this operation 1 Leakage from e The cylinder seal is damaged Replace the rack bush with a new one 2 Leakage from f There are two pos
134. 1 Suction hose 2 PipeD 3 Return hose 4 Remove the reservoir tank from the bracket by pulling it upwards 2 TURBO MODEL 1 Remove the air intake duct Ref to IN DOHC TURBO 9 REMOVAL Intake Duct 2 Drain the fluid from the reservoir tank 3 Disconnect the return hose and suction hose from the reservoir tank CAUTION Do not allow fluid from the hose end to come into contact with pulley belt e To prevent foreign matter from entering the hose cover the open ends of them with a clean cloth ST0022 1 Suction hose 2 Pipe D 3 Return hose 4 Remove the reservoir tank from the bracket by pulling it upwards B INSTALLATION 1 NON TURBO MODEL 1 Install the reservoir tank to the bracket 2 Connect the pipes D to the return hose and suc tion hose to the oil pump ST0021 1 Suction hose 2 Pipe D 3 Return hose 3 Feed the specified power steering fluid Ref to PS 72 Power Steering Fluid PS 70 RESERVOIR TANK POWER ASSISTED SYSTEM POWER STEERING 2 TURBO MODEL 1 Install the reservoir tank to the bracket 2 Connect the pressure hose and suction hose to the oil pump 570022 1 Suction hose 2 Pipe D 3 Return hose 3 Feed the specified power steering fluid lt Ref to PS 72 Power Steering Fluid gt C INSPECTION Check the reservoir tank for cracks breakage or damage any cracks breakage or damage is found replace the rese
135. 10101 Tightening torque N m kgf m ft lb 1 2 0 12 0 9 3 4 0 35 2 5 25 2 5 18 1 44 4 5 32 5 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING 2 POWER ASSISTED SYSTEM SY 21 22 689 Po Sma PS 6 39 570102 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Eye bolt Pipe C Gasket Clip Pipe D Clamp E O ring Cap Reservoir tank Reservoir tank bracket Pulley Oil pump Bracket Belt tension nut Bush Beit cover Pipe E Pipe F Clamp plate Universal joint Dust seal Valve housing Gasket Oil seal Ball bearing Seal ring GENERAL DESCRIPTION 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 POWER ASSISTED SYSTEM POWER STEERING Pinion and valve ASSY Oil seal Back up washer Ball bearing Snap ring Lock nut Adjusting screw Spring Sleeve Adapter Clamp Cotter pin Castle nut Dust cover Clip Tie rod end Clip Boot Band Tie rod Lock washer Pipe B Pipe A Steering body Oil seal Piston ring PS 7 53 54 55 56 57 58 59 Rack bushing Rack stopper Circlip Suction hose Tie rod end plate Clamp plate Tightening torque N m ft Ib T1 T2 T3 T4 T5
136. 115 116117118119120 21122 27280915041 12312419516 4 1228 The terminal numbers the ABS control module and hydraulic control unit connector as shown the figure e When the connector is removed from the ABSCM amp H U the connector switch closes the circuit between terminal No 22 and No 23 The ABS warning light illuminates ABS 14 CONTROL MODULE SIGNAL ABS DIAGNOSTICS un Terminal No eo 9 16 11 2 uis Valve relay power Supply 24 25 25 23 0 12 1 V When it is 20 Hz ABS sensor 2 Wheel speed sensor power supply 30 28 4 75 5 25 V gg output 6 28 2 3 0 2 V when the vehicle is in horizontal position Less than 1 5 V when the stop light is OFF and 10 15 V Slap when the stop light is Tom m Less than 1 5 V during 1 5 seconds when ignition switch is ON and 10 15 after 1 5 seconds AT ABS signal 2 31 23 Less than 1 5 V when the ABS control still operates and more AT model only than 5 5 V when ABS does not operate uU Less than 1 5 V when the ABS control still operates and more ABS operation signal monitor 2 3 23 Data is received 20 23 Select monitor 2 5 23 4 75 5 25 V when no data is sent ABS diagnosis connec 29 23 4 23 1 23 TT 5 51 Measure the signal voltage after removing the connector fr
137. 2002 IMPREZA SERVICE MANUAL 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 reas sembling inspection and adjustment of components and diagnostics for guid ance 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 All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD QUICK REFERENCE INDEX FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS TRANSFER CASE DRIVE SHAFT SYSTEM ABS ABS DIAGNOSTICS BRAKE PARKING BRAKE POWER ASSISTED SYSTEM POWER STEERING G1830BE5 FRONT SUSPENSION t Geperal DESCHOOM 2 2 8 3 SEO Fr MO 16 4 Front Transverse Link evi a Vn 17 9 JOU ERR TRI 19 ONE RES 20 7
138. 27380002 d 4 77 2 TIT B4M0567B 1 Alignment gauge 2 Turning radius gauge NOTE Refer to the SPECIFICATIONS for the caster val ues Ref to FS 2 SPECIFICATIONS General Description Rotate clockwise Rotate clockwise Rotate counterclock wise 4 0190 4 FRONT WHEEL e Inspection 1 Using a toe gauge measure the front wheel toe In Toe in 0 3 mm 0 0 12 2 Mark the rear sides of left and right tires at height corresponding to the center of spindles and mea sure distance A between marks 3 Move the vehicle forward so that the marks line up with front sides at height corresponding to the center of spindles 4 Measure the distance B between left and the right marks Toe in can then be obtained by the fol lowing equation A B Toe in H4M1279B Adjustment 1 Loosen the left and right side steering tie rods lock nuts FS 11 WHEEL ALIGNMENT FRONT SUSPENSION 2 Turn the left and right tie rods equal amounts un til 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 equal amounts as viewed from the in side of the vehicle S4M0348A 1 Lock nut 3 Tighten the tie rod lock nut Tightening torque a 83 N m 8 5 kgf m 61 5 ft Ib CAUTION Correct the tie rod boot if it is twisted NOTE Check that the left and right
139. 3 1 3 kgf m 9 4 ft lb 2 Connect the pipe E and F to the gearbox Tightening torque Pipe E 15 1 5 kgf m 10 8 ft lb Pipe 25 2 5 kgf m 18 1 ft lb PS 37 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 2 CONTROL VALVE ASSEMBLY Specified steering grease VALIANT GREASE 2 Part No 003608001 1 Clean all parts and tools before reassembling 2 Apply a coat of specified power steering fluid to the inner wall of valve housing S4M0162A 3 Attach ST2 to ST1 and press the oil seal into the place using a press ST1 34099FA120 INSTALLER amp REMOVER SEAL ST2 34099FA130 INSTALLER SEAL 1 Face oil seal in the direction shown in figure when installing 2 To avoid scratching oil seal apply a coat of grease to the contact surface of installer and oil seal 3 To facilitate installation attach oil seal to the installer and position in valve housing before pressing into place T 54 0160 4 Using ST and press install the special bearing valve housing ST 34099FA120 INSTALLER amp REMOVER SEAL NOTE To facilitate installation attach the ball bearing to the remover and position in valve housing before pressing it into place 54 0161 1 Special bearing 2 Oil seal 5 Put vinyl tape around pinion shaft splines to pro tect oil seal from damage 6 Fit pinion and valve assembly into valve housing 7 Secure valve assembly to
140. 3 Disconnect the connector from ABSCM amp H U 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 3 Chassis ground CHECK BATTERY SHORT OF HARNESS voltage less than 1 V Go to step 3 Repair harness 1 Turn the ignition switch to ON between TCM and 2 Measure the voltage between ABSCM amp H U ABSCM amp H U connector and chassis ground i Connector amp terminal F49 No 3 Chassis ground CHECK OPEN CIRCUIT OF HARNESS Is the voltage between 10 and Go to step 4 Repair harness 1 Turn the ignition switch to OFF 13 V 2 Connect all connectors to TCM 3 Turn the ignition switch to ON 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 3 Chassis ground F49 No 31 4 Chassis ground connector between TCM and ABSCM amp H U CHECK POOR CONTACT IN CONNECTORS there poor contact in con Repair the con Go to step 5 Turn the ignition switch to OFF nectors between TCM and nector ABSCM amp H U Is the same diagnostic trouble code as in the current diagno sis still being output CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code Replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraul
141. 383685200 3 66 0 1441 4 Install the selected pinion height adjusting shim on drive pinion and press the rear bearing cone into position with ST ST 398177700 INSTALLER 7 Insert the spacer then press fit pilot bearing with ST1 and ST2 ST1 399780104 WEIGHT ST2 899580100 INSTALLER S3M0519A 53 0520 DI 27 REAR DIFFERENTIAL DIFFERENTIALS 8 Fit a new oil seal with ST 11 Assembling differential case NOTE Install the side gears and pinion mate gears with Press fit until end of oil seal is 1 mm 0 04 in in their thrust washers and pinion mate shaft into dif ward from end of carrier ferential case Without LSD Apply grease between the oil seal lips CAUTION ST 498447120 DRIFT Apply gear oil on both sides of the washer and on the side gear shaft before installing e Insert the pinion mate shaft into the differen tial case by aligning the lock pin holes 9 Press fit the companion flange with ST1 and ST2 CAUTION careful not to damage the bearing ST1 899874100 INSTALLER ST2 399780104 WEIGHT 1 Measure the side gear backlash Side gear back clearance 227 53 0521 0 10 0 20 0 0039 0 0079 10 Install the self locking nut Then tighten it with ST ST 498427200 FLANGE WRENCH Tightening torque 181 18 5 kgf m 134 ft lb DI 28 REAR DIFFERENTIAL DIFFERENTIALS 2 Adjust the backlash as specified by select ing
142. 398467700 DRIFT 15 Remove the rear bearing cone from drive pin ion by supporting cone with ST NOTE Place the replacer so that its center recessed side faces the pinion gear REPLACER ST 398517700 S3M0512A 16 Remove the front oil seal from differential carri er using ST ST 398527700 PULLER ASSY 17 Remove the pilot bearing together with front bearing cone using ST ST 398467700 DRIFT S3M0514A A Pinion bearing B Front bearing C Rear bearing cup DI 23 REAR DIFFERENTIAL DIFFERENTIALS 18 When replacing the bearings tap front bearing cup and rear bearing cup in this order out of case by using a brass bar CER 54 NS NN AY ANNS ET A M 272 4 h Li uii Ne SS RO S3M0515A A 2 cutouts along diagonal lines B Tap alternately with brass bar D ASSEMBLY 1 Precautions for assembling e Assemble in the reverse order of disassembling e Check and adjust each part during assembly e Keep the shims and washers in order so that they are not misinstalled e Thoroughly clean the surfaces on which the shims washers and bearings are to be installed Apply gear when installing the bearings and thrust washers Be careful not to mix up the right and left hand races of the bearings e Replace the oil seal with a new one at every dis assembly Apply chassis grease between the lips when installing the oil seal 2 Adjusting pr
143. 5161716191 14 15 161171181920 1121314 1516 ma if mou 22 PREL eere 9 20 ee ee arso LL 22 1 25 26 as os 25 8 0086 5 74 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS ws Ne CHECK SPECIFICATIONS OF THE AB Replace the Go to step 2 is an ABSCM amp H U for AT SCM amp H U model installed on a MT ABSCM amp H U Check specifications of the mark to the model Ref to ABS 7 ABSCM amp H U ABS Control Mod CC AT ule and Hydraulic CD MT Control Unit ABSCM amp H U Go to step 3 Repair harness between TCM and ABSCM amp H U Go to step 4 Repair harness between TCM and ABSCM amp H U Repair harness between TCM and i CHECK GROUND SHORT OF HARNESS 1 Turn the ignition switch to OFF 2 Disconnect two connectors from TCM 3 Disconnect the connector from ABSCM amp H U 4 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp term nal F49 No 3 Chassis ground CHECK BATTERY SHORT OF HARNESS Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 3 Chassis ground CHECK BATTERY SHORT OF HARNESS 1 Turn the ignition switch to ON 2 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal
144. 606000 4 1176 1 Pin boot 2 Lock pin or guide pin 3 Apply grease 8 Install the guide pin boot on caliper body BRAKE 9 Install the lock pin boot on caliper body and in sert lock pin sleeve into place E INSPECTION NOTE Repair or replace the faulty parts 1 Check the caliper body and piston for uneven wear damage or rust 2 Check the rubber parts for damage or deteriora tion BR 29 RE ME ADT ART ema m MM REAR DRUM BRAKE SHOE BRAKE 8 Rear Drum Brake Shoe A REMOVAL 1 Loosen the wheel nuts jack up the vehicle sup port it with rigid racks and remove the wheel 2 Release the parking brake 3 Remove the brake drum from brake assembly NOTE e If it is difficult to remove the brake drum remove the adjusting hole cover from back plate and then turn the adjuster assembly pawls using a slot type screwdriver until the brake shoe separates from the drum Back plate Wheel cylinder Tightening direction Adjuster ASSY pawis Adjusting lever s Ifthe brake drum is difficult to remove drive it out by installing an 8 mm bolt into bolt hole in brake drum 4 Hold the hold down pin by securing rear of back plate with your hand S4M0451A 1 Hold down cup 2 Hold down 5 Disconnect the hold down cup from hold down pin by rotating hold down cup 6 Disconnect the lower shoe return spring from shoes 7 Remov
145. 6470000 B4M2392 DS 10 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927390000 ADAPTER Used as an adapter for AXLE SHAFT INSTALLER 922431000 v B4M2393 927400000 HOUSING STAND Used for disassembling and assembling front housing bearing Used with BEARING PULLER 927100000 B4M2394 927410000 OIL SEAL INSTALLER B4M2395 927430000 HOUSING STAND 5 0982 Used for installing oil seal into front housing e Used with HOUSING STAND 927400000 e Used for disasembling and assembling rear housing bearing e Used with BEARING PULLER 927440000 DS 11 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927120000 HUB INSTALLER Used for installing hub B4M2399 927440000 BEARING REMOVER 5 0983 927460000 OIL SEAL INSTALLER H5M0984 927450000 B4M2400 e Used for disassembling and assembling rear housing bearing Used with HOUSING STAND 927430000 Used for installing outer bearing and sub bear ing into houding Used with HOUSING STAND 927430000 HUB INSTALLER Used for installing hub unit into hub ASSY Used with BEARING SPACER 28499 000 and HUB STAND 927080000 DS 12 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28099PA090 OIL SEAL PROTEC Used for installing rear drive shaft into rea
146. 8 T2 18 1 8 13 0 3 37 3 8 27 5 T4 80 8 2 59 GENERAL DESCRIPTION BRAKE 2 REAR DISC BRAKE 10 or D lt 15 16 lt NS 26 32 BR0099 t Caliper body 14 Shim 27 Primary shoe return spring 2 Air bleeder screw 15 Shoe hold down pin 28 Adjusting spring 3 Guide pin Green 16 Cover 29 Adjuster 4 Pin boot 17 Back plate 30 Shoe hold down cup 5 Piston seal 18 Retainer 31 Shoe hold down spring 6 Piston 19 Spring washer 32 Disc rotor 7 Piston boot 20 Parking brake lever 33 Bush 8 Boot ring 21 Parking brake shoe Secondary 9 Lock pin Yellow 22 Parking brake shoe Primary Tightening torque kgf m ft lb 10 Support 23 Strut T1 8 0 8 5 8 11 Pad clip 24 Strut shoe spring 2 37 3 8 27 5 12 Inner pad 25 Shoe guide plate T3 53 5 4 39 1 13 Outer pad 26 Secondary shoe return spring BR 6 GENERAL DESCRIPTION BRAKE 3 REAR DRUM BRAKE 1 2 r 9 5 18 A 20 B4M1120A 1 2 3 4 5 6 7 8 9 10 Air bleeder cap Air bleeder screw Boot Piston Cup Spring Wheel cylinder body Pin Plug Back plate 11 12 13 14 15 16 17 18 19 20 Upper shoe return spring Retainer Washer Parking brake lever Brake shoe Trailing Brake shoe Leading Shoe hold down spring Cup Adjusting lever Adjuster BR 7 21
147. 9 2 N m 4 kgf m 28 9 ft lb CAUTION If a hose is twisted at this step the hose may come into contact with some other parts 1 Suction hose 2 PipeC 4 Connect the connector to the power steering pump switch 5 Install the pulley belt to the oil pump PS 57 OIL PUMP POWER ASSISTED SYSTEM POWER STEERING 6 Tighten the oil pump pulley nut to the specified torque Tightening torque 52 5 3 kgf m 38 ft lb 7 Check the pulley belt tension lt Ref to ME SOHC 44 INSPECTION V belt gt 8 Tighten the bolt belt tension Tightening torque 8 0 8 kgf m 5 8 ft lb 9 Install the pulley belt cover 10 Connect the ground terminal of battery 11 Feed the specified power steering fluid Ref to PS 72 Power Steering Fluid CAUTION Never start the engine before feeding the fluid otherwise vane pump might be seized up 2 TURBO MODEL 1 Install the oil pump to the bracket 1 Place the oil pump bracket in a vise Tighten the bushing using 12 7 mm 1 2 type 14 and 21 mm box wrench until it is in contact with oil pump mounting surface CAUTION Do not place oil pump bracket directly in the vise use soft pads and hold oil pump lightly to protect the pump B4M1670B 1 Bush 2 Nut 3 21mm 4 14mm 5 Bolt 2 Tighten the bolt which installs oil pump to the bracket Tightening torque 37 3 N m 3 8 kgf m 27 5 ft lb Tightening torque 15 7 N m 1 6 kg
148. A LINK 2 CONNECTOR 1 Turn the ignition switch to OFF 2 Disconnect the TCM ECM ABSCM amp H U and cruise control module connectors and connector each rol module and Jata link connec 3 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal B40 No 5 Chassis ground B40 No 4 Chassis ground CHECK OUTPUT SIGNAL FOR ABSCM amp H U 1 Turn the ignition switch to ON 2 Measure the voltage between ABSCM amp H U and chassis ground Connector amp terminal B40 No 5 Chassis ground B40 No 4 Chassis ground CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 0 5 ABSCM amp H U AND DATA LINK CONNEC TOR Measure the resistance between ABSCM amp H U connector and data link connector Connector amp terminal iepair harness to step 12 ind connector etween ABSCM amp H U and Jata link connec Or F49 No 20 B40 No 5 F49 No 5 B40 No 4 CHECK INSTALLATION OF ABSCM amp H U s the ABSCM amp H U connector 30 step 13 nsert ABSCM amp H CONNECTOR 1serted into ABSCM amp H U until J connector into s the voltage more than 1 V Repair harness ind connector etween each con rol module and Jata link connec or Turn the ignition switch to OFF he clamp locks onto it ABSCM amp H U CHECK INPUT VOLTAGE OF RELAY HOLD s the voltage more than 1
149. ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S ABSCM amp H U FRONT RH NOTE For the diagnostic procedure refer to DTC 38 lt Ref to ABS 61 DTC 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR LH Diagnostics Chart with Diagnosis Connector R DTC 34 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U FRONT LH NOTE For the diagnostic procedure refer to DTC 38 Ref to ABS 61 DTC 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR LH Diagnostics Chart with D agnosis Connector S DTC 36 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR RH NOTE For the diagnostic procedure refer to DTC 38 Ref to ABS 61 DTC 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR LH Diagnostics Chart with Diagnosis Connector T DTC 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR LH DIAGNOSIS e Faulty harness connector Faulty outlet solenoid valve in ABSCM amp H U TROUBLE SYMPTOM ABS does not operate ABS 61 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY e IGNITION SWITCH RELAY HOLDER E 314 3114 9 24 25 26 29 34 35 36 SIG 20 112113 18 28 0085 5 62 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Yes CHECK INPUT VOLTAGE OF RELAY HOLD No Repa
150. AKE ASSEMBLY BRAKE C DISASSEMBLY 4 Remove the piston seal from caliper body cylin 1 Remove the boot ring der 4M0120B 5 Remove the lock pin sleeve and boot from cali 1 Boot ring per body 2 Remove the piston boot 6 Remove the guide pin boot 3 Gradually supply compressed air via inlet of cal body to force piston out CAUTION e Place a wooden block as shown in the figure to prevent damage to piston Do not apply excessively high pressure 4 1174 1 Place 30 1 18 wide wooden block BR 28 REAR DISC BRAKE ASSEMBLY a D ASSEMBLY 1 Clean the caliper body interior using brake fluid 2 Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Insert the piston into cylinder CAUTION Do not force the piston into cylinder 5 Apply a coat of specified grease to the boot and fit in the groove on ends of cylinder and piston Grease NIGLUBE RX 2 Part No 003606000 6 Install the piston boot to the caliper body and at tach boot ring S4M0448A 1 Piston boot 2 Boot ring 3 Piston seal 4 Caliper body 7 Apply a coat of specified grease to guide pin outer surface sleeve outer surface cylinder inner surface and boot grooves Grease NIGLUBE RX 2 Part No 003
151. AUTION e Pressure gauges used exclusively for brake fluid must be used Donotemploy the pressure gauge previously used for transmission since the piston seal is expanded and may lead to malfunction of the brake NOTE Wrap a sealing tape around the pressure gauge ABS 8 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM amp H U ABS 4 Bleed air from the pressure gauges 5 Perform the ABS sequence control Ref to ABS 11 ABS Sequence Control 6 When the hydraulic unit begins to work and first the FL side performs decompression holding and compression and then the FR side performs de compression holding and compression 7 Read values indicated on the pressure gauge and check if the fluctuation of the values between decompression and compression meets the stan dard values Also check if any irregular brake pedal tightness is felt 3 432 kPa 3 432 kPa Initial value 35 kgf cm 498 35 kgf cm 498 psi psi When 490 kPa 490 kPa decom 5 kgf cm 71 psi 5kgf cm 71 psi pressed or less or less 3 432 kPa 35 498 psi or more 3 432 kPa 35 kgf cm 498 psi or more When compressed 8 Remove the pressure gauges from FL and FR caliper bodies 9 Remove the air bleeder screws from the RL and RR caliper bodies 10 Connect the air bleeder screws to the FL and FR caliper bodies 11 Connect two pressure gauges to th
152. Always replace the pads for both the left and right wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the pad wears down to such an ex tent that the end of the wear indicator contacts the disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard re place the pad Replace the pad if there is oil or grease on it BR 17 Pad thickness Standard value 17 mm 0 67 in FRONT DISC ROTOR BRAKE 3 Front Disc Rotor A REMOVAL 1 Set the vehicle on the lift 2 Loosen the wheel nuts 3 Jack up the vehicle and remove the front wheel 4 Remove the caliper body from housing and sus pend it from strut using a wire 5 Remove the disc rotor NOTE If the disc rotor seizes up within the hub drive the disc rotor out by installing an 8 mm bolt in holes B on the rotor 6 Clean mud and foreign particles from the caliper body assembly and support B INSTALLATION 1 Install the disc rotor 2 Install the caliper body on housing Tightening torque 80 8 2 kgf m 59 ft lb 3 Install the wheel C INSPECTION 1 Install the disc rotor by tightening the five wheel nuts 2 Set a dial gauge on the disc rotor Turn the disc rotor to check runout NOTE Make sure the dial gauge is set 5 mm 0 20 in in ward of rotor outer perimeter e If the runout of disc rotor
153. BS 1 Turn the ignition switch to OFF and 1 5 sensor Front 2 Disconnect the connector from ABS sensor lt Ref to ABS 14 3 Measure the resistance of ABS sensor con Front ABS Sen nector terminals sor gt Rear lt Ref Terminal to ABS 18 Rear Front RH No 1 No 2 ABS Sensor gt Front LH No 1 No 2 Rear RH No 1 No 2 Rear LH No 1 No 2 CHECK BATTERY SHORT OF ABS SEN Go to step 3 Replace the ABS sensor Front lt Ref to ABS 14 Front ABS Sen Sor Rear Ref to ABS 18 Rear ABS Sensor Go to step 4 Replace the ABS sensor Front Ref to ABS 14 Front ABS Sen sor Rear Ref to ABS 18 Rear ABS Sensor Go to step 5 Repair harness Is the voltage less than 1 V 2 Measure the voltage between ABS sensor and chassis ground Terminal Front RH No 1 Chassis ground Front LH No 1 Chassis ground Rear RH No 2 Chassis ground Rear LH 2 Chassis ground CHECK BATTERY SHORT OF ABS SEN SOR 1 Turn the ignition switch to ON 2 Measure the voltage between ABS sensor and chassis ground Terminal Front RH No 1 Chassis ground Front LH No 1 Chassis ground Rear RH No 2 4 Chassis ground Rear LH No 2 Chassis ground CHECK HARNESS CONNECTOR BETWEEN 5 the resistance between 1 ABSCM amp H U AND A
154. BS DIAGNOSTICS J DTC 28 REAR LEFT ABNORMAL ABS SENSOR SIGNAL DIAGNOSIS Faulty ABS sensor signal noise irregular signal etc Faulty harness connector TROUBLE SYMPTOM ABS does not operate ABS 111 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT f f 4 i I I Td SHIELD JOINT 1 5 REAR REAR SENSOR LH SENSOR RH ABS ABS SENSOR LH SENSOR RH 1 2 3 4 5 6 7 8 9 10 11 12 13114 15 0084 5 112 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS 1 CHECK OUTPUT OF ABS SENSOR USING speed indicated on Go to step 2 Go to step 8 SELECT MONITOR the display change in response 1 Select Current data display amp Save on the to the speedometer reading select monitor during acceleration decelera 2 Read the ABS sensor output corresponding tion when the steering wheel is to the faulty system in the select monitor data in the straight ahead position Repair the con Go to step 3 nector display mode CHECK POOR CONTACT IN CONNECTORS Go to step 4 Properly install the car telephone or Turn the ignition switch to OFF the wireless trans mitter Go to step 5 Is there poor contact in con
155. BS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Go to step 4 Go to step 5 A temporary poor contact DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ABS 158 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS AC DTC 52 MOTOR MALFUNCTION DIAGNOSIS Faulty motor e Faulty motor relay Faulty harness connector TROUBLE SYMPTOM ABS does not operate A ABS 159 A Se ee DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM Lu I o BATTERY 1 ONL 4 OAD IGNITION SWITCH ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SOLENOID VALVE FR OUTLET RL INLET RL OUTLET RR INLET HR OUTLE PUMP MOTOR FL INLET ES g FR INLET 9 141516 19 24 25 26 29 34 35 36 218 0088 Ti6 17118 19 20 21 4 123 24 25 26 5 160 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK INPUT VOLTAGE OF ABSCM amp H U 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp 3 Turn the ignition switch to ON 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49
156. BS SENSOR and 1 5 1 Turn the ignition switch to OFF 2 Connect the connector to ABS sensor 3 Measure the resistance between ABSCM amp H U connector terminals Connector amp terminal DTC 21 F49 No 11 No 12 DTC 23 F49 No 9 No 10 DTC 25 49 No 14 15 DTC 27 F49 No 7 No 8 CHECK BATTERY SHORT OF HARNESS Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal DTC 21 F49 No 11 Chassis ground DTC 23 F49 No 9 Chassis ground 25 F49 No 14 Chassis ground DTC 27 F49 No 7 Chassis ground Is the voltage less than 1 V SOR 1 Disconnect the connector from ABSCM amp between ABSCM amp H U and H U ABS sensor Is the voltage less than 1 V Repair harness between ABSCM amp H U and ABS sensor ABS 43 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS ep Gk es CHECK BATTERY SHORT OF HARNESS Isthe voltage less than 1 V Gotostep 7 Repair harness 1 Turn the ignition switch to ON between 2 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal DTC 21 F49 No 11 Chassis ground DTC 23 F49 No 9 Chassis ground DTC 25 F49 No 14 Chassis ground DTC 27 F49 No 7 Chassis ground
157. BS sensor Go to step 19 Repair harness connector between ABSCM amp H U and ABS sensor Go to step 20 Repair the ABSCM amp H U ground harness Repair the con Go to step 21 nector Is the resistance more than 1 MQ is the resistance less than 0 5 Q Is there poor contact in con nectors between ABSCM amp H U and ABS sensor is the car telephone or the wireless transmitter properly installed Go to step 22 Properly install the car telephone the wireless trans mitter Go to step 23 Install the noise sources apart from the sensor har ness Go to step 24 CHECK SOURCES OF SIGNAL NOISE Are noise sources such as an antenna installed near the sensor harness Is the resistance less than 0 5 Q CHECK SHIELD CIRCUIT 1 Connect all connectors 2 Measure the resistance between shield con nector and chassis ground Connector amp terminal DTC 26 B200 No 11 Chassis ground DTC 28 B200 No 3 Chassis ground NOTE For the DTC 22 and 24 Go to step 24 CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code Repair the shield harness Is the same diagnostic trouble code as in the current d agno sis still being output Replace the ABSCM amp H U Ref to ABS 7 ABS
158. BSCM amp H U connector and chassis ground Connector amp terminal F49 No 1 4 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Go to step 8 Go to step 9 Repair the ABSCM amp H U ground harness Connector amp terminal F49 No 23 Chassis ground CHECK POOR CONTACT IN CONNECTORS 15 there poor contact in con Repair the con Go to step 10 nectors between generator nector battery and ABSCM amp H U CHECK ABSCM amp H U Is the same diagnositc trouble Replace the Go to step 11 1 Connect all connectors code as in the current diagno ABSCM amp H U Is the voltage between 10 and 15 V Repair harness connector between ABS relay and ABSCM amp H U is the resistance less than 0 5 Q 2 Erase the memory sis still being output lt Ref to 5 7 3 Perform the inspection mode ABS Control Mod 4 Read out the diagnostic trouble code ule and Hydraulic Control Unit ABSCM amp H U gt ABS 59 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble Proceed with the temporary poor codes being output diagnosis corre sponding to the diagnostic trouble code ABS 60 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Q DTC 32
159. C PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA150 CARTRIDGE Troubleshooting for electrical systems Newly adopted tool B2M3876 22771 AA030 SELECT MONITOR Troubleshooting for electrical systems English 22771AA030 Without printer German 22771AA070 Without printer French 22771 AA080 Without printer e Spanish 22771AA090 Without printer B2M3877 2 GENERAL PURPOSE TOOLS TOOL NAME REMARKS Used for measuring resistance voltage and ampere Oscilloscope Used for measuring sensor ABS 10 GENERAL DESCRIPTION ABS DIAGNOSTICS ABS 11 ELECTRICAL COMPONENTS LOCATION ABS DIAGNOSTICS 4 Electrical Components Location A LOCATION 8 1 ABS control module and hydraulic 5 Data link connector for Subaru 8 control unit ABSCM amp H U select monitor 9 2 Proportioning valve 6 Transmission control module only 10 3 Diagnosis connector AT vehicle 11 4 ABS warning light 7 Tone wheel 12 ABS 12 BRO0031 ABS sensor Wheel cylinder G sensor Stop light switch Master cylinder ELECTRICAL COMPONENTS LOCATION ABS DIAGNOSTICS B4M1226B 0056 BRO109 BRO057 0058 5 13 CONTROL MODULE SIGNAL ABS DIAGNOSTICS 5 Control Module I O Signal A ELECTRICAL SPECIFICATION ABS control module and hydraulic control unit connector Connector switch 11213141516171819 10 1112113114
160. CK WIRING HARNESS 1 Disconnect the connector F74 from con nector B200 2 Turn the ignition switch to ON CHECK PROJECTION AT ABSCM amp H U 1 Turn the ignition switch to OFF 2 Check for broken projection at the ABSCM amp H U terminal Replace the ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Are the projection broken ABS 35 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Yes CHECK ABSCM amp H U Is the resistance more than 1 to step 10 Replace the Measure the resistance between ABSCM amp H U ABSCM amp H U terminals lt Ref to ABS 7 Terminal ABS Control Mod No 22 No 23 ule and Hydraulic Control Unit ABSCM amp H U gt CHECK WIRING HARNESS Is the resistance less than 0 5 Go to step 11 Repair the har Measure the resistance between connector ness F74 and chassis ground Connector amp terminal F74 No 20 Chassis ground CHECK WIRING HARNESS Is the resistance more than 1 Go to step 12 Repair the har 1 Connect the connector to ABSCM amp H U MQ ness 2 Measure the resistance between connector F74 and chassis ground Connector amp terminal F74 No 20 Chassis ground CHECK POOR CONTACT ABSCM amp H U Is there poor contact in Repair the con Replace the CONNECTOR ABSCM amp H U connector nector ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and H
161. CM amp H L and ABS sensor s the car telephone or the vireless transmitter properly nstalled ABS 50 20 to step 8 20 to step 10 Replace the ABS sensor Front Ref to ABS 14 Front ABS Sen sor Rear Ref to ABS 18 Rear ABS Sensor E LJ Replace the tone wheel Front Ref to ABS 21 Front Tone Wheel Rear Ref to ABS 22 Rear Tone Wheel Replace the ABS sensor Front Ref to ABS 14 Front ABS Sen sor Rear Ref to ABS 18 Rear ABS Sensor 30 to step 11 Repair harness connector between ABSCM amp H U and ABS sensor 30 to step 12 Repair harness connector between ABSCM amp H U and ABS sensor 3o to step 13 Repair the ABSCM amp H U ground harness lepair the con Go to step 14 iector 20 to step 15 Properly install the car telephone or the wireless trans mitter DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS _ CHECK SOURCES OF SIGNAL NOISE Are noise sources such as an nstall the noise o to step 16 antenna installed near the sources apart from sensor harness he sensor har 1658 CHECK SHIELD CIRCUIT Is the resistance less than 0 5 3o to step 17 Repair the shield 1 Connect all connectors Q larness 2 Measure the resistance between shield con nector and chassis ground Connector amp terminal DTC 26 B200 No 11 Chassis ground DTC 28 B200 No 3 Chassis
162. CM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS B ABS WARNING LIGHT DOES NOT GO OFF DIAGNOSIS ABS warning light circuit is open or shorted TROUBLE SYMPTOM When starting the engine and while the ABS warning light is kept ON ABS 33 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY SBF 3 SBF 1 p c x o e E IGNITION SWITCH 9 e RELAY HOLDER D No 13 8 TURBO ENGINE MODEL NON TURBO ENGINE 2 MODEL h COMBINATION METEN DIAGNOSIS TERMINAL 9 BiG 20 30 11112113 28 38 516 RELAY HOLDER 0083 ABS 34 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Ye No O 1 CHECK INSTALLATION OF ABSCM amp H U Is the ABSCM amp H U connector Go to step 2 Insert ABSCM amp H U connector into ABSCM amp H U until the clamp locks onto it the diagno sis terminal har ness inserted into ABSCM until the clamp locks onto it CONNECTOR Turn the ignition switch to OFF Is the resistance less than 0 5 2 CHECK DIAGNOSIS TERMINAL Measure the resistance between diagnosis ter minals B81 and chassis ground Terminals Diagnosis terminal A Chassis ground Diagnosis terminal B
163. CRIPTION PARKING BRAKE 1 General Description A SPECIFICATIONS Reardscbrke Lining dimensions 219 3 x 35 0 x 4 1 length x width x thickness 8 63 x 1 378 x 0 161 6 42 x 1 181 x 0 126 PB 2 GENERAL DESCRIPTION PARKING BRAKE B COMPONENT 1 PARKING BRAKE REAR DISC BRAKE B4M1127A 1 Back plate 10 Primary return spring Tightening torque kgf m ft lb 2 Retainer 11 Secondary return spring T 53 5 4 39 3 Spring washer 12 Adjusting spring 4 Lever 13 Adjuster 5 Parking brake shoe Primary 14 Shoe hold down cup 6 Parking brake shoe Secondary 15 Shoe hold down spring 7 Strut spring 16 Shoe hold down pin 8 Strut 17 Adjusting hole cover 9 Shoe guide plate PB 3 GENERAL DESCRIPTION PARKING BRAKE E 2 PARKING BRAKE CABLE 4 0705 1 Parking brake lever 7 Clamp Tightening torque kgf m ft lb 2 Parking brake switch 8 Parking brake cable RH T1 6 0 6 4 4 3 Lock nut 9 Cable guide T2 18 1 8 13 0 4 Adjusting nut 10 Clamp Rear disc brake model T3 33 3 4 24 5 Equalizer only 6 Bracket 11 Parking brake cable LH PB 4 GENERAL DESCRIPTION PARKING BRAKE C CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during opera tion Remove contamination including dirt and corro sion before removal installation or disassem
164. CTION Check the pad thickness A 54 0187 Pad thickness including back Standard value 14 0 mm 0 551 in metal CAUTION e Always replace the pads for both the left and right wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the pad wears down to such an ex tent that the end of the wear indicator contacts the disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard re place the pad Replace the pad if there is oil or grease on it BR 24 REAR DISC ROTOR BRAKE 6 Rear Disc Rotor A REMOVAL 1 Lift up the vehicle and remove the wheels 2 Remove the two mounting bolts and remove the disc brake assembly 3 Suspend the disc brake assembly so that the hose is not stretched 4 Pull down and release the parking brake 5 Remove the disc rotor NOTE If the disc rotor is difficult to remove try the follow ing two methods in order 1 Turn the adjusting screw using a slot type screwdriver until the brake shoe gets away enough from the disc rotor 54 0569 1 Adjusting screw 2 Cover 3 Slot type screwdriver 4 Back plate 2 If the disc rotor seizes up within hub drive the disc rotor out by installing an 8 mm bolt in holes B on the rotor B INSTALLATION 1 Install in the reverse order of removal
165. Connect the ABSCM amp H U connector 3 Disconnect the ECM connector 4 Check whether communication to other sys tems such as TCM engine etc can be exe cuted normally CHECK COMMUNICATION OF SELECT MONITOR 1 Turn the ignition switch to OFF 2 Connect the ECM connector 3 Disconnect the TCM connector 4 Check whether communication to other sys tems such as engine etc can be executed normally CHECK COMMUNICATION OF SELECT MONITOR 1 Turn the ignition switch to OFF 2 Connect the TCM connector 3 Disconnect the cruise control module con nector 4 Check whether communication to other sys tems such as engine TCM etc can be exe cuted normally NOTE If the vehicle is not equipped with cruise control 7 Go to step 9 Are the name and year of the system displayed on the select monitor Are the name and year of the system displayed on the select monitor Are the name and year of the system displayed on the select monitor Are the name and year ofthe Inspect the TCM system displayed on the select monitor Inspect the cruise control module Are the name and year of the system displayed on the select monitor ABS 97 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 to step 10 3epair harness EACH CONTROL MODULE AND DAT
166. Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code Go to step 25 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary noise interference ABS 115 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ABS 116 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS K DTC 29 ABNORMAL ABS SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR DIAGNOSIS e Faulty ABS sensor signal noise irregular signal etc e Faulty tone wheel e Wheels turning freely for a long time TROUBLE SYMPTOM e ABS does not operate y ABS 117 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM SHIELD JOINT CONNECTOR ETE A mom ae Zt p i m m 51 E ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SENSOR RH f i t 1 i t 1 I i 5 SENSOR LH SENSOR RH SENSOR LH B99 0084 ABS 118 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Check
167. DRIVE SHAFT SYSTEM C INSPECTION NOTE Do not disassemble propeller shaft Check the fol lowing and replace if necessary 1 Tube surfaces for dents or cracks 2 Splines for deformation or abnormal wear 3 Joints for non smooth operation or abnormal noise 4 Center bearing for free play noise or non smooth operation 5 Oil seals for abnormal wear or damage 6 Center bearing for breakage Check the following points with propeller shaft in stalled in vehicle 1 JOINTS AND CONNECTIONS 1 Remove the rear exhaust pipes and muffler 2 Remove the heat shield cover If equipped 3 Check for any looseness of yoke flange connect ing bolts and center bearing retaining bolts 2 SPLINES AND BEARING LOCATIONS 1 Remove the rear exhaust pipe and muffler 2 Remove the heat shield cover equipped 3 Turn the propeller shaft by hand to see if abnor mal free play exists at splines Also move yokes to see if the abnormal free play exists at spiders and bearings 3 RUNOUT OF PROPELLER SHAFT 1 Remove the rear exhaust pipe and muffler 2 Remove the heat shield cover If equipped 3 Turn the rear wheels by hand to check for runout of propeller shaft NOTE Measure runout with a dial gauge at the center of front and rear propeller shaft tubes Runout Limit 0 6 mm 0 024 in B3M1603A A Propeller shaft B Dial gauge 4 CENTER BEARING FREE PLAY 1 Remove the rear exhaust pipe and muf
168. E Make sure there is no clearance between the case and ST2 ST1 398507702 DUMMY SHAFT DIFFERENTIAL CARRIER GAUGE ST2 398507701 H3M1309B _ 3 Obtain the thickness of pinion height adjust ing shim to be inserted from the following formu la and replace the temporarily installed shim with this one T To N H x 0 01 0 20 mm 0 0079 in NOTE Use copies of this page T Thickness of shim temporarily inserted mm in To Thickness of pinion height adjusting shim mm in Reading of thickness gauge in Figure marked on drive pinion head Memo Example of calculation To 2 20 1 202 3 40 mm N 0 23 mm H 1 T 3 40 0 23 0 01 0 20 3 42 Result Thickness 3 42 mm Therefore use the shim 383605200 DI 26 REAR DIFFERENTIAL DIFFERENTIALS 5 Insert the drive pinion into differential carrier in stall the previously selected bearing preload adjust ing spacer and washer 21 383595200 3 39 0 1335 B3M0560B 383605200 3 42 0 1346 A Drive pinion Bearing adjusting spacer 383625200 3 48 0 1370 C Washer at de e ede D Differential carrier 383645200 3 54 0 1394 383655200 3 57 0 1406 6 Press fit the front bearing cone into case with i 383665200 3 60 0 1417 11 ST2 and 513 ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER 383675200 3 63 0 1429
169. ECIAL TOOLS PREPARA TION TOOL General Description gt 4 Connect the Subaru Select Monitor to data link connector 1 Data link connector is located in the lower portion of the instrument panel on the driver s side 2 Connect the diagnosis cable to data link connector 5 Turn the ignition switch to ON engine OFF and Subaru Select Monitor switch to ON S2M0288D 1 Power switch 6 On the Main Menu display screen select the Each System Check and press the YES key 7 On the System Selection Menu display screen select the Brake Control System and press the YES key 8 Press the YES key after displayed the informa tion of engine type 9 On the ABS Diagnosis display screen select the Diagnostic Code s Display and press the YES key 10 On the Diagnostic Code s Display display screen select the Current Diagnostic Code s or History Diagnostic Code s and press the YES key NOTE e For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MAN UAL e For detailed concerning diagnostic trouble codes DTC refer to the LIST OF DIAGNOSTICS TROU BLE CODE Ref to ABS 24 List of Diag nostics Trouble Code DTC gt ABS 18 SUBARU SELECT MONITOR ABS DIAGNOSTICS 2 READ CURRENT DATA 1 On the Main Menu display screen select the Each System Check and press the YES key 2 On the System Selection Menu display s
170. ECK ANY OTHER DIAGNOSTIC other diagnostic trouble Proceed with the temporary poor BLE CODES APPEARANCE codes being output diagnosis corre sponding to the diagnostic trouble code ABS 128 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ABS 129 E clu cla ee eee DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS T DTC 41 ABS CONTROL MODULE MALFUNCTION DIAGNOSIS Faulty ABSCM amp H U TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS CONTROL MODULE HYDRAULIC CONTROL UNIT ABS 130 B4M1457 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR CHECK GROUND CIRCUIT OF ABSCM amp H U Is the resistance less than 0 5 to step 2 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Measure the resistance between ABSCM amp H U and chassis ground Connector amp terminal F49 No 23 Chassis ground CHECK ABSCM amp H U 1 Turn the ignition switch to OFF 2 Connect all connectors 3 Erase the memory 4 Perform the inspection mode 5 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE 115 there poor contact in con nectors between battery igni tion switch and ABSCM amp H U Is the car tele
171. EEL AND TIRE SYSTEM 3 Steel Wheel A REMOVAL 1 Apply the parking brake and position select le ver to P or LOW 2 Set the shop jacks or a lift to the specified point and support the vehicle with its wheels slightly con tacting the floor 3 Loosen the wheel nuts 4 Raise the vehicle until its wheels take off the ground using a jack or a lift 5 Remove the wheel nuts and wheels NOTE While removing the wheels prevent hub bolts from damage NOTE e Place the wheels with their outer sides facing up ward to prevent wheels from damage B INSTALLATION 1 Attach the wheel to the hub by aligning the wheel bolt hole with the hub bolt 2 Temporarily attach the wheel nuts to the hub bolts In the case of aluminum wheel use SUBA RU genuine wheel nut for aluminum wheel 3 Manually tighten the nuts making sure the wheel hub hole is aligned correctly to the guide portion of hub 4 Tighten the wheel nuts in a diagonal selection to the specified torque Use a wheel nut wrench Wheel nut tightening torque 90 9 1 kgf m 65 7 ft Ib CAUTION Tighten the wheel nuts in two or three steps by gradually increasing the torque and working diagonally until the specified torque is reached For drum brake models excess tight ening of wheel nuts may cause wheels to jud der Do not depress the wrench with a foot Al ways use both hands when tightening Make sure the bolt nut and the
172. ERAL DESCRIPTION DRIVE SHAFT SYSTEM 2 FRONT DRIVE SHAFT ASSEMBLY shaftassemby EBJ87 SFJ82 B Measuring point DS 3 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 3 REAR DRIVE SHAFT ASSEMBLY Type of drive shaft assembly Posen on a EBJ82 DOJ82 E EBJ82 DOJ82 LH Ge BJ79 DOJ79 RH BJ79 DOJ79 LH IRA MR E 98 EBJ62 D0J82 29 38 24 82 2082 R Wagon Turbo 1 oa EBJ82 DOJ82 LH BJ79 DOJ79 RH BJ79 DOJ79 LH Wagon Non turbo inc 1 Identification protrusion DS 4 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM B COMPONENT 1 PROPELLER SHAFT DROO14 1 Propeller shaft Turbo model 4 Bush Tightening torque N m kgf m ft lb 2 Propeller shaft Non Turbo model 5 Bush T1 31 3 2 23 1 3 Rear differential 2 52 5 3 38 3 DS 5 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 2 FRONT AXLE 4 3 13 B4M2213A 1 Baffle plate 5 9 Boot SFJ 17 Housing 2 Spring pin 10 Boot EBJ 18 Oil seal OUT 3 Outer race SFJ 11 EBJ ASSY 19 Hub bolt 4 Snap ring 12 Tone wheel With ABS 20 Hub 5 Trunnion 13 Baffle plate 21 Axle nut 6 Free ring 14 seal IN 7 Circlip 15 Snapring Tightening torque N m kgf m ft Ib 8 Boot band 16 Bearing 186 19 137 DS 6 3 REAR AXLE 1 2
173. F ABSCM amp H U 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCMAH U connector and chassis ground Connector amp terminal F49 No 23 Chassis ground Is the resistance less than 5 Q Replace the ABS relay Is the resistance less than 10 Q Repair harness connector between battery ignition switch and ABSCM amp H U Is the voltage between 10 and 15 V Repair the ABSCM amp H U ground harness Is the resistance less than 0 5 Repair the con nector 118 there poor contact con Go to step 10 nectors between generator battery and ABSCM amp H U CHECK ABSCM amp H U 1 the same diagnostic trouble Replace the 1 Connect all connectors code as in the current diagno ABSCM amp H U Go to step 11 2 Erase the memory sis still being output Ref to 5 7 3 Perform the inspection mode ABS Control Mod 4 Read out the diagnostic trouble code ule and Hydraulic Control Unit ABSCM amp H U ABS 123 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK ANY OTHER DIAGNOSTIC TROU other diagnostic trouble Proceed with the A temporary poor BLE CODES APPEARANCE codes being output diagnosis corre sponding to the diagnostic trouble code ABS 124 DIAGNOSTICS CHART WITH SUBARU SE
174. FER DRIVEN GEAR MT TRANSFER CASE 6 Transfer Driven Gear MT A NOTE For removal installation and inspection work refer to MT section lt Ref to MT 47 Transfer Driven Gear TC 7 REDUCTION DRIVE GEAR WITHOUT VTD TRANSFER CASE 7 Reduction Drive Gear without VTD A NOTE For removal installation and inspection work refer to AUTOMATIC TRANSMISSION a separate publication Pub No G0853ZE TC 8 REDUCTION DRIVE GEAR WITH VTD TRANSFER CASE 8 Reduction Drive Gear with VTD A NOTE For removal installation and inspection work refer to AUTOMATIC TRANSMISSION a separate publication Pub G0853ZE 9 REDUCTION DRIVEN GEAR WITHOUT VTD TRANSFER CASE 9 Reduction Driven Gear with out VTD A NOTE For removal installation and inspection work refer to AUTOMATIC TRANSMISSION a separate publication Pub 208532 TC 10 REDUCTION DRIVEN GEAR WITH VTD TRANSFER CASE 10 Reduction Driven Gear with VTD A NOTE For removal installation and inspection work refer to AUTOMATIC TRANSMISSION a separate publication Pub No G0853ZE TC 11 CENTER DIFFERENTIAL TRANSFER CASE 11 Center Differential A NOTE For removal installation and inspection work refer to AUTOMATIC TRANSMISSION a separate publication or MT section AT model Pub G0853ZE MT model Ref to MT 49 Center Differential TC 12
175. GEAR OIL DIFFERENTIALS 2 Differential Gear Oll A INSPECTION 1 Take out the filler plug and replace gear oil if it is contaminated or deteriorated lt Ref to DI 17 RE PLACEMENT Differential Gear Oil gt 2 Check gear oil level is up to the bottom part of fill er bolt If the level is low refill up to the bottom of filler bolt DRO0017 em A Filler plug B Drain plug B REPLACEMENT 1 Disconnect the ground terminal from battery 2 Jack up the vehicle and support it with sturdy racks 3 Remove the oil drain plug and filler plug and drain the gear oil CAUTION Be careful not to burn your hands because gear oil becomes extremely hot after running A Filler plug B Drain plug 4 Tighten the oil drain plug NOTE Apply fluid packing to the drain plug Fluid packing THHEE BOND 1105 or equivalent Tightening torque 49 0 N m 5 0 kgf m 36 2 ft Ib 5 Fill differential carrier with gear oil to the upper plug level CAUTION Carefully refill while watching the level Ex cess or insufficient oil must be avoided Oil capacity 0 8 0 0 8 US qt 0 7 Imp qt A Filler plug B Drain plug 6 Install the filler plug NOTE Apply fluid packing to the filler plug Fluid packing THREE BOND 1105 or equivalent Tightening torque 49 0 N m 5 0 kgf m 36 2 ft Ib DI 17 FRONT DIFFERENTIAL DIFFERENTIALS 3 Front Differential A NOTE 1 AT MODEL
176. H u OUTPUT DIAGNOSIS e Faulty G sensor output voltage TROUBLE SYMPTOM ABS does not operate ESTES ie nns E g ABS 175 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR C KE 1 1 guo IQ ABS G SENSOR BAHE BR0090 ABS 176 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK OUTPUT OF G SENSOR USING SE s the G sensor output on mon Go to step 2 Go to step 6 LECT MONITOR itor display 2 3 0 2 V when the 1 Select Current data display amp Save on the sensor is in horizontal posi select monitor tion 2 Read the G sensor output on the select mon itor display CHECK POOR CONTACT IN CONNECTORS Turn the ignition switch to OFF Repair the con nector Is there poor contact in con nector between ABSCM amp H U and G sensor Is the same diagnostic trouble code as in the current diagno sis still being output Go to step 4 CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code Replace the ABSCM amp H U Ref to ABS 7 ABS Contr
177. HECK INSTALLATION OF ABS SENSOR Tightening torque 32 N m 3 3 kgf m 24 ft Ib CHECK ABS SENSOR GAP Measure the tone wheel to ABS sensor piece gap over entire perimeter of the wheel Tighten the ABS sensor installation bolts securely Go to step 10 Adjust the gap NOTE Adjust the gap us Is the gap within the specifica tions Front wheel ing spacer Part 0 3 0 8 mm 0 012 0 031 in No 26755AA000 Hear wheel If spacers cannot correct the gap re place the worn sensor or worn tone wheel 10 PREPARE OSCILLOSCOPE Is an oscilloscope available 0 7 1 2 mm 0 028 0 047 in ABS 113 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK ABS SENSOR SIGNAL Is the oscilloscope pattern Go to step 15 Go to step 12 1 Raise all four wheels of ground smooth as shown in the fig 2 Turn the ignition switch OFF ure 3 Connect the oscilloscope to the connector 4 Turn the ignition switch ON 5 Rotate the wheels and measure voltage at specified frequency lt Ref to ABS 17 WAVE FORM Control Module Signal NOTE When this inspection is completed the AB SCM amp H U sometimes stores the DTC 29 Connector amp terminal 22 F95 1 No 2 24 F94 No 1 No 2 DTC 26 B99 9 10 DTC 28 B99 4 5 CHECK CONTAMINATION OF ABS SENSOR Is the
178. IGHT FRONT AND REAR CAMBER FRONT AND REAR CASTER FRONT FRONT TOE IN REAR TOE IN THRUST ANGLE REAR WHEEL STEERING ANGLE B4M1088A FS 8 WHEEL ALIGNMENT FRONT SUSPENSION 1 WHEEL ARCH HEIGHT 1 Adjust the tire pressure to specifications 2 Set the vehicle under curb weight conditions Empty luggage compartment install spare tire jack ser vice tools and top up fuel tank 3 Set the steering wheel in a wheel forward position 4 Suspend a thread from wheel arch point A in figure below to determine the point directly above center of spindle 5 Measure the distance between measuring point A and center of spindle Outer Front fender rear quarter Wheel arch height D lt o 9 5 Cross section of arch Front wheel arch height Rear wheel arch height Wheel arch height 500009 Specified wheel arch height Rear 376 12 mm 14 8040 47 in 381412 mm 1504047 Rear 376 12 mm 14 80 0 47 in 98 1EZ mm 15 00 47 in SO nh 386412 15 2050 47 ___ 5 9 WHEEL ALIGNMENT FRONT SUSPENSION 2 CAMBER Inspection 1 Place the front wheel on turning radius gauge Make sure the ground contacting surfaces of front and rear wheels are set at the same height 2 Set the ST into the center of the wheel and then install the wheel alignment gauge ADAPTER ST 927380002 1 A
179. IS e Faulty stop light switch TROUBLE SYMPTOM e ABS does not operate WIRING DIAGRAM BATTERY SBF 1 FAL me Of ot 2 E o STOP LIGHT SWITCH B lo O 5 5 WITHOUT CRUISE CONTROL WITH CRUISE CONTROL ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT Lr g 112 6 7 819 1011 12 13 14 15 1121314 1 1516 7 8 9 NET 101111213 14 15 16 17j18 19 20 22 deie s p nr 25 28 0089 5 86 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS CHECK STOP LIGHTS COME ON Do the stop lights come on Go to step 2 Repair the stop Depress the brake pedal lights circuit 1 2 CHECK OPEN CIRCUIT IN HARNESS Is the voltage between 10 and Go to step 3 Repair harness 15 V 1 Turn the ignition switch to OFF between stop light 2 Disconnect the connector from ABSCM amp switch and Is there poor contact in con Repair the con nector between stop light nector H U ABSCM amp H U switch and ABSCM amp H U 3 Depress the brake pedal 4 Measure the voltage between ABSCM amp H U Is the same diagnostic trouble code as in the current diagno connector and chassis ground sis still being output Connector amp terminal F49 No 2 Chassis ground Go to step 4 Go to step 5 temporary poor contact Replace the ABSCM amp
180. Inflate to correct pressure 7 Disordered wheel alignment Adjust alignment 8 Loosened back plate or the support installing Retighten olts 9 Loosened wheel bearing 10 Trouble in the hydraulic system 11 Uneven effect of the parking brake Correct or replace 2 Unstable or uneven braking JU etighten to normal tightening torque or replace eplace the cylinder brake pipe or hose Check adjust or replace the rear brake and cable system 1 Entry of air into the hydraulic mechanism Bleed the air 2 Excessive play in the master cylinder push rod Adjust 3 Fluid leakage from the hydraulic mechanism Repair or replace cup piston seal piston boot master cylinder piston kit pipe or hose Adjust Correct or replace Adjust play Clean or replace the cylinder 3 Excessive pedal stroke 4 Improperly adjusted shoe clearance 5 Improper lining contact or worn lining 1 Insufficient pedal play 2 Improper master cylinder return 3 Clogged hydraulic system Replace 4 improper return or adjustment of parking brake Correct or adjust 5 Weakened spring tension or breakage of shoe Replace the spring return spring 6 Excessively narrow shoe clearance Adjust the clearance 7 Improper disc caliper operation Correct or replace 8 Improper adjusted wheel bearing Adjust or replace 1 Hardened or deteriorated lining Replace the shoe assembly or pad 4 Br
181. LECT MONITOR ABS DIAGNOSTICS P DTC 32 FRONT RIGHT OUTLET VALVE MALFUNCTION NOTE For the diagnostic procedure refer to DTC 38 Ret to ABS 125 38 REAR LEFT OUTLET VALVE MALFUNCTION Diagnostics Chart with Subaru Select Monitor gt Q DTC 34 FRONT LEFT OUTLET VALVE MALFUNCTION NOTE For the diagnostic procedure refer to DTC 38 lt Ref to ABS 125 DTC 38 REAR LEFT OUTLET VALVE MALFUNCTION Diagnostics Chart with Subaru Select Monitor R DTC 36 REAR RIGHT OUTLET VALVE MALFUNCTION NOTE For the diagnostic procedure refer to DTC 38 lt Ref to ABS 125 DTC 38 REAR LEFT OUTLET VALVE MALFUNCTION Diagnostics Chart with Subaru Select Monitor gt S DTC 38 REAR LEFT OUTLET VALVE MALFUNCTION DIAGNOSIS Faulty harness connector e Faulty outlet solenoid valve TROUBLE SYMPTOM ABS does not operate ABS 125 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY GENERATOR IGNITION SWITCH RELAY e _ 0085 HHEIDBEDHPEIBENNE 29124 125 128 ABS 126 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ER 1 Turn the ignition switch to OFF 2 Remove the fuse 3 Measure the voltage between ABS relay connector and chassis ground Connector amp terminal B225 5 Chassis ground 1 CHECK INPUT VOLTAGE OF RELAY HOLD is
182. Lower shoe return spring 22 Adjusting spring 23 Drum Tightening torque N m kgf m ft lb T1 8 0 8 5 8 2 10 1 0 7 2 T3 53 5 4 39 1 GENERAL DESCRIPTION BRAKE 4 MASTER CYLINDER B4M0325B 1 Cap 6 Secondary piston Tightening torque N m kgf m ft Ib 2 Filter 7 Cylinder body 1 14 1 4 10 1 3 Reservoir tank 8 Cylinder pin with ABS 4 Piston retainer 9 Seal 5 Primary piston 10 Pin 8 GENERAL DESCRIPTION BRAKE 5 FRONT BRAKE PIPES AND HOSE BRO0077 1 Front brake pipe assembly 6 Gasket Tightening torque N m kgf m ft Ib 2 Proportioning valve 7 ABS control module and hydraulic T1 15 1 5 10 8 3 Front brake hose RH control unit T2 18 1 8 13 0 4 Front brake hose LH 8 Bracket T3 32 3 3 23 6 5 9 Master Cylinder BR 9 6 CENTER AND REAR BRAKE PIPES AND HOSE 1 2 3 4 5 Clamp Center brake pipe assembly Two way connector Rear brake pipe assembly Rear brake hose RH Disc brake model GENERAL DESCRIPTION 6 7 8 0078 Rear brake hose RH Drum brake 9 Gasket model Rear brake hose LH Disc brake Tightening torque kgf m ft lb model 1 15 1 5 10 8 Rear brake hose LH Drum brake T2 18 1 8 13 0 model BR 10 GENERAL DESCRIPTION BRAKE 7 BRAKE BOOSTER 4 1974 1 Push rod 5 Filter 9 Valve body 2 Retu
183. N 6 Measure the voltage between G sensor con nector terminals Connector amp terminal 8292 2 No 3 CHECK G SENSOR Measure the voltage between G sensor con nector terminals Connector amp terminal 292 No 2 No 3 Is the voltage between 3 7 and Go to step 9 4 1 V when G sensor is inclined forwards to 90 Replace the G sensor lt Ref to ABS 23 G Sen sor gt ABS 177 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS 1 Is the voltage between 0 5 and Go to step 10 Replace the G Measure the voltage between G sensor con 0 9 V when G sensor is Sensor lt Ref to nector terminals inclined backwards to 90 ABS 23 G Sen Connector amp terminal sor gt B292 No 2 3 CHECK ABSCM amp H U Is the same diagnostic trouble Replace the Go to step 11 1 Turn the ignition switch to OFF code as in the current diagno ABSCM amp H U 2 Connect all connectors sis still being output Ref to ABS 7 3 Erase the memory ABS Control Mod 4 Perform the inspection mode ule and Hydraulic 5 Read out the diagnostic trouble code Control Unit ABSCM amp H U CHECK ANY OTHER DIAGNOSTIC TROU other diagnostic trouble Proceed with the A temporary poor BLE CODES APPEARANCE codes being output diagnosis corre contact sponding to the diagnostic trouble code ABS 178 DIAGNOSTICS CHART WITH SUBARU
184. N Be careful not to damage these pipes NOTE Disconnect the upper pipe D first and lower pipe C second m 54 0382 1 Pipe 2 Pipe D PS 26 STEERING GEARBOX 13 Remove the clamp bolts securing gearbox to the crossmember and remove the gearbox S4M0383A 1 Clamp B INSTALLATION 1 Insert the gearbox into the crossmember being careful not to damage gearbox boot 2 Tighten the gearbox to the crossmember bracket via clamp with bolt to the specified torque Tightening torque 59 6 0 kgf m 43 ft lb UE S4M0383A 1 Clamp 3 Install the four pipes on the gearbox 1 Connect the pipes A and B to the four pipe joints of gearbox Connect the upper pipe B first and lower pipe A Tightening torque 13 N m 1 3 kgf m 9 4 ft lb POWER ASSISTED SYSTEM POWER STEERING 2 Connect the pipes C and D to the gearbox Connect the upper pipe D first and lower pipe C second Tightening torque 15 N m 1 5 kgf m 10 8 ft lb S4M0382A 1 Pipe C 2 Pipe D 4 Install the universal joint Ref to PS 20 IN STALLATION Universal Joint 5 Connect the tie rod end and knuckle arm and tighten with castle nut Fit the cotter pin into the nut and bend the pin to lock Castle nut tightening torque Tighten to 27 0 N m 2 75 kgf m 19 9 ft Ib and tighten further within 60 until cotter pin hole is aligned with a slot in the nut CAUTION When connecting do
185. NDOHC TURBO 8 IN STALLATION Air Intake Duct 11 Connect the battery ground terminal PS 50 PIPE ASSEMBLY POWER ASSISTED SYSTEM POWER STEERING 12 Feed the specified fluid NOTE Never start the engine before feeding the fluid otherwise vane pump might be seized up S4M0272B 1 High pressure hose 3 Clearance between crossmember 2 interference is allowed and pipe 3 8 mm 0 12 0 31 between hoses in 13 Finally check clearance between pipes and or hoses as shown above If the clearance between cruise control pump and power steering hose is less than 10 mm 0 39 in proceed as follows 1 Move the clamped section A refer to fig ure above down to a point where the pipe is close to crossmember Pipe to crossmember clearance 10 mm 0 39 in min 2 Check that clearance between cruise con trol pump and power steering hose is at least 10 mm 0 39 in If it is not bend section B down until a clearance of at least 10 mm 0 39 in is obtained PS 51 PIPE ASSEMBLY POWER ASSISTED SYSTEM POWER STEERING C INSPECTION Check all disassembled parts for wear damage or other abnormalities Repair or replace faulty parts as re quired e O ring fitting surface for damage Nut for damage Pipe for damage with new one Replace with new one Flared surface for damage Flare nut for damage Outer surface for cracks Outer surface
186. NSPECTION 1 ABS SENSOR 1 Check the pole piece of the ABS sensor for for eign particles or damage If necessary clean the pole piece or replace the ABS sensor 2 Measure the ABS sensor resistance Standard 172520 25 CAUTION If resistance is outside the standard value place the ABS sensor with a new one NOTE Check the ABS sensor cable for discontinuity If necessary replace with a new one 2 SENSOR GAP 1 Measure the distance A between ABS sensor surface and sensor pole face B4M2482A 2 Measure the distance B between the surface where front axle housing meets the ABS sensor and the tone wheel NOTE Measure so that the gauge touches the tone wheel teeth top p Ww 54 0510 1 Axle housing 2 Tone wheel 3 Find the gap between the ABS sensor pole face and the surface of the tone wheel teeth by putting the measured values in the formula below and cal culating ABS sensor clearance ABS sensor standard clearance 0 3 0 8 mm 0 012 0 031 in NOTE If the clearance is outside specifications readjust ABS 16 FRONT ABS SENSOR ABS 3 OUTPUT VOLTAGE D ADJUSTMENT Output voltage can be checked by the following Adjust the gap using spacer Part No 26755A000 method Install a resistor and condenser then ro tate the wheel about 2 75 km h 2 MPH or equiva lent NOTE Regarding terminal No please refer to item 1 ABS
187. NSPECTION Front Axle gt CAUTION The lean of axis direction Do not apply pressure more than 3 92 KN 0 4 Maximum 0 05mm 0 0020in ton 0 4 US ton 0 4 Imp ton 2 Inspect the removed parts for wear and damage If defective replace with a new one CAUTION If a bearing is faulty replace it as the bearing set Be sure to replace oil seal at every overhaul 54 0269 9 Apply the sufficient grease to oil seal lip aceles A Specified grease SHELL 6459N CAUTION If specification grease is not available re move bearing grease and apply Auto Rex A in stead Do not mix different types of grease 10 Install back plate to rear housing H4M1002C A Replace as a set Tightening torque 52 N m 5 3 kgf m 38 ft lb 11 Using ST1 and ST2 press the baring into hub ST1 927080000 STAND ST2 927450000 HUBINSTALLER CAUTION Do not apply pressure more than 25 KN 2 5 ton 2 3 US ton 2 5 Imp ton 54 0270 DS 31 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM 5 Front Drive Shaft A REMOVAL 1 Disconnect the ground cable from battery 2 Jack up the vehicle support it with safety stands rigid racks and remove the front wheel cap and wheels 3 Unlock the axle nut 4 Depress the brake pedal and remove the axle nut using a socket wrench CAUTION Be sure to loosen and retighten axle nut after removing wheel from vehicle Failure to follow this rule may damag
188. No 25 Chassis ground CHECK GROUND CIRCUIT OF MOTOR 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 26 Chassis ground CHECK INPUT VOLTAGE OF ABSCM amp H U 1 Run the engine at idle 2 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 1 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 23 Chassis ground CHECK MOTOR OPERATION Operate the sequence control Ref to ABS 11 ABS Sequence Control NOTE Use the diagnosis connector to operate the se quence control CHECK POOR CONTACT IN CONNECTORS Turn the ignition switch to OFF CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Repair harness connector between battery and ABSCM amp H U and check fuse SBF6 Is the voltage between 10 and 13 V Go to step 2 30 to step 6 Repair the ABSCM amp H U ground harness 15 the resistance less than 0 5 Q Repair harness connector between battery
189. OINT i CONNECTOR I i 1 i i 1 JL ZI 4 mie 1 I i 1 I 1 I 1 I 4 1 i t t 1 I I 1 1 1 i 1 I I I 1 I 1 I 1 FRONT FRONT ABS ABS REAR REAR SENSOR LH SENSOR RH ABS SENSOR LH SENSOR RH a 9 cepa PII ra BUT fnejrzpe toto 24 25 0084 BO 5 106 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Check Yes CHECK OUTPUT OF ABS SENSOR USING oes the speed indicated on 30 to step 2 30 to step 8 SELECT MONITOR he display change in response 1 Select Current data display amp Save on the 5 the speedometer reading select monitor luring acceleration decelera 2 Read the ABS sensor output corresponding ion when the steering wheel is to the faulty system in the select monitor data the straight ahead position display mode CHECK INSTALLATION ABS SENSOR re the ABS sensor installation 30 to step 3 Tighten the ABS sensor installation bolts securely Tightening torque 32 3 3 kgf m 24 ft lb CHECK ABS SENSOR GAP Measure th
190. OJ from rear differential using ST ST 28099PA100 DRIVE SHAFT REMOVER NOTE The side spline shaft circlip comes out together with the shaft 1 2 CAUTION Bolt DOJ B4M1685A Be careful not to damage the side bearing re tainer Always use bolt as shown in figure as supporting point for ST during removal ST 28099PA100 DRIVE SHAFT REMOVER 1 Side bearing retainer DS 39 REAR DRIVE SHAFT DRIVE SHAFT SYSTEM B INSTALLATION 6 Align the DOJ and differential splines 1 Insert the BJ EBJ into the rear hub splines i dd the housing to insert DOJ into the differen ial CAUTION NOTE Be careful not to damage tone wheel 2 Using ST1 and ST2 pull the drive shaft into the place ST1 922431000 AXLE SHAFT INSTALLER ST2 927390000 ADAPTER CAUTION Do not hammer drive shaft when installing it Make sure the DOJ is inserted properly CAUTION Discard old self locking nut Replace with a new one 8 While depressing brake pedal tighten the axle B4M1690A nut using a socket wrench 3 Tighten the axle nut temporarily Tightening torque 4 Using ST install the DOJ into differential 235 N m 24 kgf m 174 ft Ib ST 28099PA090 SIDE OIL SEAL PROTEC CAUTION TOR e Use a new axle nut for rear use only Always tighten axle nut before installing wheel on vehicle If wheel is installed and comes in contact with ground when axle nut is loose wheel bearings may be damaged e Be s
191. OR ABS DIAGNOSTICS Ye Ns s the voltage between 10 and 30 to step 2 Repair the genera 15 V tor Ref to SC 13 Generator CHECK GENERATOR 1 Start the engine 2 dling after warm up 3 Measure the voltage between generator B terminal and chassis ground Terminal Generator B terminal Chassis ground CHECK BATTERY TERMINAL Turn the ignition switch to OFF Are the positive and negative terminals tightly clamped s the voltage between 10 and 15 Tighten the clamp of terminal CHECK INPUT VOLTAGE OF ABSCM amp H U 1 Disconnect the connector from ABSCM amp 2 Run the engine at idle 3 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 1 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 23 Chassis ground Repair harness connector between battery ignition switch anc ABSCM amp H U 30 to step 4 30 to step 5 Repair the ABSCM amp H U ground harness to step 3 s the resistance less than 0 5 22 CHECK POOR CONTACT IN CONNECTORS s there poor contact con 1epair the con Go to step 6 rectors between generator
192. POSAL Refer to Front Strut as a guide for disposal proce dures lt Ref to FS 23 DISPOSAL Front Strut gt RS 15 LATERAL LINK REAR SUSPENSION 6 Lateral link A REMOVAL 1 Loosen the wheel nuts Lift up the vehicle and remove wheel 2 Remove the stabilizers Turbo model 3 Remove the ABS sensor harness from trailing link Models eqipped with ABS 4 Remove the bolt securing trailing link to housing B4M0573B 1 Rear housing 2 Trailing link 5 Remove the bolts which secure lateral link as sembly to rear housing 6 Remove the DOJ from rear differential using ST ST 28099PA100 DRIVE SHAFT REMOVER NOTE The side spline shaft circlip comes out together with the shaft 27 1 Bolt 2 DOJ CAUTION Be careful not to damage the side bearing re tainer Always use bolt shown in figure as sup porting point for ST during removal 7 Scribe an alignment mark on the rear lateral link adjusting bolt and crossmember 8 Remove the bolis securing front and rear lateral links to crossmember detach lateral links CAUTION To loosen the adjusting bolt always loosen the nut while holding the head of adjusting bolt B INSTALLATION Install in the reverse order of removal Observe the following instructions Installation of DOJ to differential lt Ref to 05 40 INSTALLATION Rear Drive Shaft gt CAUTION Do not allow the DOJ splines to damage side oil
193. POWER STEERING 3 RACK SHAFT PLAY IN RADIAL DIREC TION Right turn steering Service limit When making a measurement vise gearbox by us 0 19 mm 0 0075 in or less ing ST Never vise gearbox by inserting aluminum plates etc between vise and gearbox ST 926200000 STAND Sliding resistance of rack shaft Service limit 340 N 35 kgf 76 Ib or less i 27 On condition L 5 0 20 122 6 N 12 5 kof 27 6 G4M0111 Left turn steering Service limit Direction lt 0 3 mm 0 012 in or less Direction 0 15 mm 0 0059 in or less 5mm 0 20 Uf 10 kgf 22 Ib G4M0112 PS 43 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 4 INPUT SHAFT PLAY 5 TURNING RESISTANCE OF GEARBOX In radial direction Using ST measure gearbox turning resistance Service limit ST 34099PA100 SPANNER 0 18 mm 0 0071 in or less Service limit On condition Maximum allowable resistance In axial direction Service limit 0 5 mm 0 020 in or less On condition P 20 49 N 2 5 kof 4 11 Ib PS 44 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 6 OIL LEAKING 1 4 3 2 1 Power cylinder 3 Rack piston 2 Cylinder 4 Rack axle NOTE If the gearbox is dismounted without confirming where the leak is it must be mounted again to lo cate the leak point
194. RELAY Replace the ABS 1 Connect the battery to ABS relay terminal relay No 1 and 3 2 Measure the resistance between ABS relay terminals CHECK POWER SUPPLY CIRCUIT Is the voltage more than 10 V to step 20 Repair open circuit 1 Turn the ignition switch to ON engine OFF in harness 2 Measure the ignition power supply voltage between between ABSCM amp H U connector and chassis ABSCM amp H U and ground battery Connector amp terminal F49 1 Chassis ground CHECK HARNESS CONNECTOR BETWEEN 15 the resistance less than 1 Go to step 21 Repair open circuit ABSCM amp H U AND CHASSIS GROUND Q in harness 1 Turn the ignition switch to OFF between 2 Disconnect the connector from ABSCM amp H U ABSCM amp H U and and transmission inhibitor side con 3 Measure the resistance of harness between nector and poor ABSCM amp H U and chassis ground contact in cou Connector amp terminal pling connector F49 No 23 Chassis ground Is there poor contact in control Repair the con Replace the module power supply ground nector ABSCM amp H U line and data link connector Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt ABS 99 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Ee E C o a Re AY ce On c EF MEE
195. Rear LH No 1 No 2 CHECK GROUND SHORT OF ABS SENSOR Measure the resistance between ABS sensor and chassis ground Terminal Front RH No 1 Chassis ground Front LH No 1 Chassis ground Rear RH No 1 Chassis ground Rear LH No 1 Chassis ground CHECK HARNESS CONNECTOR BETWEEN ABSCM amp H U AND ABS SENSOR 1 Connect the connector to ABS sensor 2 Disconnect the connector ABSCM amp H U 3 Measure the resistance at ABSCM amp H U connector terminals Connector amp terminal DTC 22 F49 No 11 12 DTC 24 F49 9 No 10 26 F49 14 15 DTC 28 F49 No 7 No 8 CHECK GROUND SHORT OF HARNESS Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal 22 F49 No 11 Chassis ground DTC 24 F49 No 9 Chassis ground DTC 26 F49 No 14 Chassis ground DTC 28 F49 No 7 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U Measure the resistance between ABSCM amp H U and chassis ground Connector amp terminal F49 No 23 GND CHECK POOR CONTACT IN CONNECTORS CHECK SOURCES OF SIGNAL NOISE s the resistance between 1 ind 1 5 s the resistance more than 1 the resistance between 1 1 5 5 the resistance more than 1 AQ s the resistance less than 0 5 2 s there poor contact in con rectors between ABS
196. Remove the two bolts securing housing to strut CAUTION While holding the head of adjusting bolt loosen self locking nut 5 20 FRONT STRUT FRONT SUSPENSION B INSTALLATION 1 Install the strut mount at upper side of strut to body and tighten with nuts Tightening torque 20 2 0 kgf m 14 5 ft lb 2 Position the aligning mark on camber adjustment bolt with aligning mark on lower side of strut CAUTION e While holding the head of adjusting bolt tighten self locking nut e Be sure to use a new self locking nut Tightening torque 175 17 8 kgf m 129 ft lb 3 install the ABS sensor harness to strut Tightening torque 33 3 4 kgf m 24 3 ft lb 4 Install bolts which secure the brake hose to strut _ lightening torque 33 3 4 kgf m 24 3 ft lb 5 Instail the front wheels NOTE Check wheel alignment and adjust if necessary C DISASSEMBLY 1 Using a coil spring compressor compress the coil spring 2 Using the ST remove the self locking nut ST 927760000 STRUT MOUNT SOCKET 54 0096 3 Remove the strut mount upper spring seat and rubber seat frorn strut 4 Gradually decreasing the compression force and remove the coil spring 5 Remove the dust cover and helper spring FS 21 FRONT STRUT FRONT SUSPENSION D ASSEMBLY 1 Before installing the coil spring strut mount etc on the strut check for the presence of air in the dampening
197. SELECT MONITOR ABS DIAGNOSTICS AH DTC 56 DETECTION OF G SENSOR STICK DIAGNOSIS e Faulty G sensor output voltage TROUBLE SYMPTOM ABS does not operate ABS 179 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SHIELD JOINT CONNECTOR e Gm um m PPP 5 SENSOR 2 1 2 7 10111 12113 14 15 1213 11 2 3 4 Bitumen 5161718 pag EON 25 26 0090 5 180 TELS NE anes DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS oa Ye _ Have the wheels been turned The ABS is nor step 2 freely such as when the vehicle Erase the diagnostic trouble code Go to step 3 is lifted up or operated on a Go to step 4 Replace the G rolling road CHECK OUTPUT SENSOR USING SE 15 the sensor output on the sensor Ref to ABS 23 G Sen LECT MONITOR monitor display between 2 1 sor gt CHECK ALL FOUR WHEELS FOR FREE TURNING 1 Select Current data display amp Save on the and 2 5 V when the vehicle is select monitor in horizontal position 2 Read the select monitor
198. STICS Check Yes Check if the wheels have been The ABS is nor turned freely for more than one Erase the minute such as when the vehi diagnostic trouble cle is jacked up under full lock code cornering or when tire is not in NOTE contact with road surface When the wheels turn freely for long t me such as when the vehicle is towed or jacked up or when steer ing wheel is contin uously turned all the way this trou bie code sometimes occur 2 CHECK TIRE SPECIFICATIONS Are the tire specifications cor Go to step 3 Replace the tire Turn the ignition switch to OFF rect CHECK IF THE WHEELS HAVE TURNED FREELY FOR A LONG TIME Go to step 2 3 CHECK WEAR OF TIRE is the tire worn excessively Replace the tire 4 CHECK TIRE PRESSURE Is the tire pressure correct Go to step 5 Adjust the tire pressure 5 CHECK INSTALLATION OF ABS SENSOR Are the ABS sensor installation to step 6 Tighten the ABS Tightening torque bolts tightened securely sensor installation 32 3 3 kgf m 24 ft Ib bolts securely CHECK ABS SENSOR GAP Is the gap within the specifica Go to step 7 Adjust the gap Measure the tone wheel to ABS sensor piece tions NOTE gap over entire perimeter of the wheel Adjust the gap us Specifications ing spacer Part Front wheel No 26755AA000 0 3 0 8 0 012 0 031 in If spacers cannot Rear wheel correct the gap re
199. SYSTEM 3 Clean the housing interior completely Using ST1 and ST2 press the bearing into the housing 5 1 927430000 HOUSING STAND ST2 927440000 BEARING REMOVER CAUTION e Always press iouter race when installing bearing careful not to remove plastic lock from in ner race when installing bearing e Charge bearing with new grease when outer race is not removed Do not apply pressure more than 30 KN 3 1 ton 2 8 US ton 3 1 Imp ton 54 0266 4 Using plier install the snap ring CAUTION Ensure snap ring fits in groove properly gu S4M0371A 5 Using ST1 and ST2 press the outer oil seal unit it comes in contact with snap ring ST1 927430000 HOUSING STAND ST2 927460000 OIL SEAL INSTALLER CAUTION Do not apply pressure more than 3 92 KN 0 4 ton 0 4 US ton 0 4 Imp ton S4M0267B 1 Snap ring 6 Invert both ST1 and housing 7 Using ST2 press the inner oil seal into the hous ing until it touches bottom ST1 927430000 HOUSING STAND SI2 927460000 OIL SEAL INSTALLER CAUTION Do not apply pressure more than 3 92 KN 0 4 ton 0 4 US ton 0 4 Imp ton 54 0268 05 30 REAR AXLE DRIVE SHAFT SYSTEM 8 Using ST1 and ST2 press the sub seal into INSPECTION place 1 Inspect the rattle and lean of axis direction of the ST1 927430000 HOUSING STAND removed parts as the same procedure of Front Axle ST2 927460000 OIL SEAL INSTALLER lt Ref to DS 22 I
200. T6 T7 T8 T9 T10 T11 T12 T13 T14 T15 T16 T17 T18 6 0 6 4 3 7 4 0 75 5 4 8 0 8 5 8 13 1 3 9 4 15 1 5 10 8 15 1 5 10 8 15 7 1 6 11 6 22 2 2 15 9 24 2 4 17 4 25 2 5 18 1 25 2 5 18 1 27 2 75 19 9 37 3 3 8 27 5 39 4 0 28 9 59 6 0 43 78 8 0 58 83 8 5 61 5 25 2 5 18 1 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING 3 OIL PUMP NON TURBO MODEL 21 2 3 10 510005 1 Pulley 10 Pressure switch 19 O ring 2 seal 11 O ring 20 Rear cover 3 Shaft 12 O ring 21 Suction connector 4 Connector 13 Pressure plate 5 O ring 14 Straight pin Tightening torque kgf m ft lb 6 Spool valve 15 Vane 1 21 2 14 15 5 7 Spring 16 Rotor T2 49 5 0 36 2 8 O ring 17 ring T3 52 5 3 38 9 Front casing 18 Retaining ring PS 8 TURBO MODEL GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING Lead wire Pump switch Rear cover O ring Cam Pressure plate O ring Front casing 9 10 11 12 13 14 15 16 Front casing Flow control spring Flow control valve Pulley Oil seal Suction connector O ring Retaining ring PS 9 17 5 0006 O ring Tightening torque N m kgf m ft Ib T1 T2 T3 T4 T5 9 8 1 0 7 2 27 2 75 19 9 27 4 2 8 20 3 59 6 0 43 11 8 1 2 8 7 GENERAL DESCRIPTION POWER ASSIS
201. TAL LATION Console Box gt PB 7 PARKING BRAKE CABLE PARKING BRAKE 3 Parking Brake Cable A REMOVAL 1 Lift up the vehicle 2 Remove the rear tires and wheels 3 Remove the rear cushion 4 Remove the console box lt Ref to El 41 RE MOVAL Console Box gt 5 Loosen the parking cable adjusting nut and con sole bracket 6 Remove the parking brake lever 8 Remove the equalizer cover 9 Remove the inner cable end from equalizer S4M0473A 1 Equalizer 2 Inner cable end 10 Pull out the parking brake cable from rear brake Disc brake lt Ref to PB 10 REMOVAL Parking Brake As sembly Rear Disc Brake gt Drum brake lt Ref to BR 33 Rear Drum Brake Assembly gt 11 Pull out the clamp from rear brake 12 Remove the bolt and bracket from trailing link bracket 13 Remove the bolt and clamp from rear floor S4M0474A 1 Grommet 2 Parking brake cable 14 Detach the grommet from rear floor 15 Remove the cable assembly from cabin by forc ibly pulling it backward 16 Detach the parking brake cable from cable guide at rear trailing link PB 8 PARKING BRAKE CABLE PARKING BRAKE B INSTALLATION C INSPECTION Install the new parking brake assembly in the re Check the removed cable and replace if damaged verse order of removal rusty or malfunctioning 1 Check for smooth operation of the cable 2 Check the inner cable for damage and rust 3 Check the out
202. TED SYSTEM POWER STEERING C CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during opera tion e Remove contamination including dirt and corro sion before removal installation or disassembly Keep the disassembled parts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part on the vehicle is hot after running e Use SUBARU genuine steering fluid grease etc or the equivalent Do not mix steering fluid grease etc with that of another grade or from other manu facturers Be sure to tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or safety stands at the specified points e Apply steering fluid onto sliding or revolution sur faces before installation Before installing O rings or snap rings apply suf ficient amount of steering fluid to avoid damage and deformation Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice PS 10 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925700000 WRENCH e Used for removing and installing tie
203. TEM POWER STEERING 7 Remove the screw securing lower steering col umn cover sf ims lt v A 8 Remove the knee bolster 9 Remove all connectors from the steering col umn 10 Remove the two bolts under instrument panel securing steering column 11 Pull out the steering shaft assembly from the hole on toe board CAUTION Be sure to remove the universal joint before re moving steering shaft assembly installing bolts when removing steering shaft assembly or when lowering it for servicing of other parts B INSTALLATION 1 Set the grommet to the toe board 2 Insert the end of steering shaft into the toe board grommet 3 Tighten the steering shaft mounting bolts under instrument panel Tightening torque 25 N m 2 5 kgf m 18 1 ft Ib 4 install the knee bolster 5 Connect all connectors under instrument panel 6 Connect the airbag system connector at the har ness spool NOTE Make sure to apply double lock 7 Install the lower column cover with tilt lever held in the lowered position 8 Install the universal joint Ref to PS 20 IN STALLATION Universal Joint 9 Align the center of roll connector Ref to AB 17 ADJUSTMENT Roll Connector CAUTION Ensure that front wheels are set in straight for ward direction PS 24 TILT STEERING COLUMN 10 Install the steering wheel lt Ref to PS 19 IN STALLATION Steering Wh
204. TION FOR INITIALIZING IMPOSSI tializing impossible nication failure BLE Diagnostics Chart with Subaru Select Monitor gt Although no trouble code appears on the No trouble code select monitor display the ABS warning light remains on Open or short circuit in Open or short circuit in Ref to ABS 104 DTC 21 OPEN OR SHORT CIRCUIT IN FRONT 21 front right ABS sensor front right ABS sensor RIGHT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru circuit circuit Select Monitor 22 Front right ABS sensor Front right ABS sensor Ref to ABS 110 DTC 22 FRONT RIGHT ABNORMAL ABS SEN abnormal signal abnormal signal SOR SIGNAL Diagnostics Chart with Subaru Select Monitor 23 Ref to ABS 101 NO TROUBLE CODE Diagnostics Chart with Subaru Select Monitor Open or short circuit in Open or short circuit in Ref to ABS 104 DTC 23 OPEN OR SHORT CIRCUIT IN FRONT front left ABS sensor front left ABS sensor LEFT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru Select circuit circuit Monitor 24 Front left ABS sensor Front left ABS sensor Ref to ABS 110 DTC 24 FRONT LEFT ABNORMAL ABS SEN abnormal signal abnormal signal SOR SIGNAL Diagnostics Chart with Subaru Select Monitor 25 Open or short circuit in Open or short circuit in Ref to ABS 104 DTC 25 OPEN OR SHORT CIRCUIT IN REAR rear right ABS sensor rear right ABS sensor RIGHT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru
205. TTERY SHORT OF ABS WARN ING LIGHT HARNESS 1 furn the ignition switch to ON 2 Measure the voltage between connector F74 and chassis ground Connector amp terminal F74 No 19 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U Measure the resistance between ABSCM amp H U and chassis ground Connector amp terminal F49 No 23 GND CHECK WIRING HARNESS Measure the resistance between connector F74 and chassis ground Connector amp terminal F74 No 19 Chassis ground Is the voltage less than 3 V Repair the warning light harness Go to step 6 Repair the wiring harness Go to step 7 Repair the wiring harness Go to step 8 Go to step 9 Repair the ABSCM amp H U ground harness Go to step 10 Repair the har Is the voltage less than 3 V Repair the warning light harness Is the voltage between 10 and 15 V Is the voltage less than 3 V is the voltage less than 3 V Repair the wiring harness Is the resistance less than 0 5 Q Is the resistance less than 0 5 Q ness connector ABS 31 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS CHECK POOR CONTACT IN CONNECTORS 15 there poor contact in con Repair the con Turn the ignition switch to OFF nectors between combination nector meter and ABSCM amp H U ABS 32 Replace the ABS
206. Take off the DOJ cage from shaft and remove DOJ boot CAUTION Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches 12 Remove the BJ or EBJ boot in the same proce dure as DOJ boot 13 Thus disassembly of axle is completed but BJ or EBJ is unable to be disassembled DS 41 REAR DRIVE SHAFT DRIVE SHAFT SYSTEM ASSEMBLY CAUTION Use specified grease BJ side Non turbo model Molylex No 2 Part No 723223010 EBJ side Turbo model NTG 2218 Part No 28093AA000 DOJ side VU 3A702 Yellow Part No 23223GA050 1 Install the BJ or EBJ boot in specified position and fill it with 60 to 70 g 2 12 to 2 47 oz of speci fied grease 2 Place the DOJ boot at the center of shaft CAUTION Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches 3 Insert the DOJ cage onto shaft NOTE Insert the cage with the cut out portion facing the shaft end since the cage has an orientation 54 0376 Cage Cut out portion 4 Install the DOJ inner race on shaft and fit snap ring with pliers NOTE Confirm that the snap ring is completely fitted in the shaft groove 5 Install the cage which was previously fitted to inner race fixed upon shaft NOTE Fit the cage with the protruded part aligned with the track on the inner race and then turn by a haif pitch 4 0228 A Inner race B Cage 6 Fill 80 to 90 g 2 82 to 3 17 oz
207. Used for press fitting the front bearing cone pilot bearing 3 1900 DI 9 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock REMOVER 9in B3M1901 498247001 MAGNET BASE Used for measuring backlash between side jear and pinion and hypoid gear Used with DIAL GAUGE 498247100 B3M1902 498247100 DIAL GAUGE Used for measurng backlash between side year and pinion and hypoid gear Used with MAGNET BASE 498247001 B3M1903 398507704 BLOCK Jsed for adjusting pinion height and preload B3M1904 01 10 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOLNUMBER DESCRIPTION REMARKS 1 398177700 INSTALLER e Used for installing rear bearing cone B3M1905 398457700 ATTACHMENT Used for removing side bearing retainer B3M1906 398477703 DRIFT2 Used for press fitting the bearing race rear of differential carrier B3M1907 398437700 DRIFT e Used for installing side oil seal B3M1908 01 11 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507702 DUMMY SHAFT Used for adjusting pinion height and preload B3M1909 398507703 DUMMY COLLAR Used for adjusting pinion height and preload B3M1910 398517700 REPLACER Used for removing rear bearing cone B3M1911 398487700 DRIFT Used for press fitting the side bea
208. Wear or damage of 7 Deformation of stabilizer clamp RS 20 WHEEL AND TIRE SYSTEM 1 General Description 11111 nnne RENE 3 Do ade mu nel 4 Aluminum 1 101 enne rene nennen 5 Wheel 0 meer 6 T type Tire 0 1 0 11 21 000 enne 7 Full Wheel 00 8 General Diagnostics Table senem GENERAL DESCRIPTION WHEEL AND TIRE SYSTEM 1 General Description A SPECIFICATIONS i S4M0367A 1 Offset 2 Rimsi Rim offset mm in mm in P195 60R15 87H 15 x Front and rear P205 55 R16 89V 16 x 6 1 2JJ 55 2 17 buo 215 45 R17 87W 17 x 7JJ T Type tire T135 70 D16 100M 16 x 4T 50 1 97 Fr 220 2 2 32 m P195 60 R15 87H Rr 200 2 0 29 205 55 R16 89 Fr 220 2 2 32 Rr 200 2 0 29 215 45 R17 87W Fr 230 2 3 33 Rr 220 2 2 32 T Type tire 1135 70 D16 100M 420 4 2 60 NOTE T type tire for temporary use is supplied as a spare tire WT 2 GENERAL DESCRIPTION
209. Yes Check if the wheels have been The ABS is nor turned freely for more than one mal Erase the minute such as when the vehi diagnostic trouble cle is jacked up under full lock code cornering or when tire is not in NOTE contact with road surface When the wheels tum freely for a long time such as when the vehicle is towed or jacked up or when steer ing wheel is contin uously turned the way this diag nostic trouble code may sometimes occur 2 CHECK TIRE SPECIFICATIONS Are the tire specifications cor to step Replace the tire Turn the ignition switch to OFF rect 3 WEAR OF TIRE Is the tire worn excessively Replace the tire to step 4 4 CHECK TIRE PRESSURE Is the tire pressure correct Go to step 5 Adjust the tire pressure CHECK INSTALLATION OF ABS SENSOR the ABS sensor installation to step 6 Tighten the ABS bolts tightened securely Tightening torque sensor installation 32 N m 3 3 kgf m 24 ft lb bolts securely Is the gap within the specifica to step 7 tions CHECK IF THE WHEELS HAVE TURNED FREELY FOR A LONG TIME Go to step 2 CHECK ABS SENSOR GAP Adjust the gap Measure the tone wheel to ABS sensor piece NOTE gap over entire perimeter of the wheel Adjust the gap us Front wheel ing spacer Part 0 3 0 8 mm 0 012 0 031 in No 26755 00
210. acceleration Yes 9 No aerem 7 C Engine stalls e Occurrence of vibration Yes No Others What kind e What kind Behavior of vehicle ABS 7 CHECK LIST FOR INTERVIEW ABS DIAGNOSTICS 3 CONDITIONS Environment Condition Brakes Accelerator m Vehicle speed Ly Advancing LJ Accelerating C Reducing speed Q Low speed Turning Others d Tire inflation pressure 6 Degree of wear UNDER WHICH TROUBLE OCCURS Fine Cloudy Rainy Li Snowy J Various Others b Ambient temperature Road Urban area Suburbs LJ Highway General road 1 Ascending slope 1 Descending slope Paved road _J Gravel road LJ Muddy road A Sandy place J Others 4 Dry Wet LI New fallen snow Compressed snow Frozen slope Others a Weather d Road surface Rear RH GENUINE parts are used 2 Yes No ABS 8 GENERAL DESCRIPTION ABS DIAGNOSTICS 3 General Description A CAUTION 1 SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG The airbag system wiring harness is routed near the ABS sensor ABS control module and hydraulic control unit CAUTION All Airbag system wiring harness con nectors are colored yellow Do not use electri cal test equipment on these circuit e Be careful not to damage the Airbag sys
211. ake dragging or improper brake return 5 Brake noise 1 creak sound 2 Worn lining Replace the shoe assembly or pad 3 Loosened back plate or the support installing Retighten bolts 4 Loose wheel bearing Retighten to normal tightening torque 5 Dirty drum or rotor Clean the drum or rotor or clean and replace the brake assembly Replace the shoe assembly or pad Correct or replace the shoe assembly or pad Retighten or replace 6 Brake noise 2 hissing sound 1 Worn lining 2 Improper installed shoe or pad 3 Loose or bent drum or rotor i T 41 GENERAL DIAGNOSTICS BRAKE 7 Brake noise 3 click sound Trouble and possible cause Corrective action In the case of the disc brake 1 Excessively worn pad or the support Replace the pad or the support In the case of the drum brake 1 Excessively worn shoe ridge Replace the back plate 2 Lack of oil on the shoe ridge surface and Add more grease anchor BR 58 1 General DeSCFHHDLOLD ooi SUN 2 2 Parking Brake Lever ettet ak vai as edo aep ne Vl Rr rd eua aera Ens 6 3 Parking Brake 8 4 Parking Brake Assembly Rear Disc Brake 10 5 General Diagnostic Table c optet 13 GENERAL DES
212. ar LH No 1 Chassis ground Ref to ABS 14 ABS 114 Are there broken or damaged in the ABS sensor piece or the tone wheel Front ABS Sen sor Rear Ref to ABS 18 Rear ABS Sensor Replace the ABS sensor Front Ref to ABS 14 Front ABS Sen Sor Rear Ref to ABS 18 Rear ABS Sensor DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS _ 17 CHECK HARNESS CONNECTOR BETWEEN 15 the resistance between 1 Go to step 18 Repair harness ABSCM amp H U AND ABS SENSOR and 1 5 kQ 1 Connect the connector to ABS sensor 2 Disconnect the connector from ABSCM amp H U 3 Measure the resistance at ABSCM amp H U connector terminals Connector amp terminal DTC 22 F49 No 11 No 12 DTC 24 F49 No 9 No 10 DTC 26 F49 No 14 No 15 DTC 28 F49 No 7 No 8 CHECK GROUND SHORT OF HARNESS Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal DTC 22 F49 No 11 Chassis ground DTC 24 F49 No 9 Chassis ground DTC 26 F49 No 14 Chassis ground DTC 28 F49 No 7 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U Measure the resistance between ABSCM amp H U and chassis ground Connector amp terminal F49 No 23 GND CHECK POOR CONTACT IN CONNECTORS connector between ABSCM amp H U and A
213. arily tighten bolts CAUTION Discard the loosened self locking nut and re place with a new one 5 Tighten the following points in the order shown below when the wheels are in full contact with the ground and vehicle is curb weight 1 Transverse link and stabilizer Tightening torque Sedan Turbo model 45 4 6 kgf m 33 ft lb Except sedan Turbo model 30 3 1 kgf m 22 ft lb 2 Transverse link and crossmember Tightening torque 100 10 2 kgf m 74 ft lb 3 Transverse link rear bushing and body Tightening torque 250 25 5 kgf m 184 ft Ib FS 17 FRONT TRANSVERSE LINK FRONT SUSPENSION NOTE e Move the rear bushing back and forth until trans verse link to rear bushing clearance is established as indicated in figure before tightening Unit mm in 1 5 0 059 S4M0352A 1 Rear bushing 6 Install the sub frame lt Ref to FS 16 INSTALLA TION Sub Frame gt 7 Inspect the wheel alignment and adjust if neces sary lt Ref to FS 8 Wheel Alignment gt C DISASSEMBLY 1 FRONT BUSHING Using ST press the front bushing out of place ST 927680000 INSTALLER amp REMOVER SET G4M0494 2 REAR BUSHING 1 Scribe an aligning mark on the transverse link and rear bushing 2 Loosen the nut and remove the rear bushing D ASSEMBLY 1 FRONT BUSHING To reassemble reverse disassembly procedures CAUTION Install the front bushing in
214. assembly into valve housing assembly Used with STAND BASE 927630000 4 2421 926390001 COVER amp e Used for assembling rack assembly REMOVER ASSY 4 2422 926420000 PLUG When oil leaks from pinion side of gearbox assembly remove pipe B from valve housing attach this tool and check oil leaking points B4M2423 926400000 GUIDE e Right side of rack when installing rack bush e Used with GUIDE 927660000 4 2424 5 14 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927660000 GUIDE Right side of rack when installing rack bush Used with GUIDE 926400000 B4M2425 927620000 INSTALLER B B4M2426 926360000 INSTALLER A B4M2428 34099FA110 INSTALLER B4M2429 PS 15 Used for installing oil seal of valve housing Used with INSTALLER A 926360000 Used as guide to install oil seal Used with INSTALLER B 927620000 Used for installing oil seal GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34099FA120 INSTALLER AND Used for installing and removing valve housing REMOVER SEAL oil seal 51 0030 34099 130 INSTALLER SEAL e Used for installing valve housing oil seal e Used with INSTALLER AND REMOVER SEAL 34099FA120 510007 34199AE050 B4M2432 34099AC030 INSTALLER A Used for installing retaining ring Used with INSTALLER B 34099 040
215. ation first These repeat for a maximum of 3 minutes NOTE When there are no diagnostic trouble code DTC in memory only the start code 11 is shown When on board diagnosis of the ABS control module detects a problem the information up to a maximum of three will be stored in the EEP ROM as a diagnostic trouble code DTC When there are more than three the most recent three will be stored Stored codes will stay in memory until they 1 Diagnosis connector are cleared 2 Diagnosis terminals 3 3 terminal 4 6 terminal 1 1 0 5222 22 722 0 3 Start code Start code Start code 0081 2 WITH SUBARU SELECT MONITOR Refer to SUBARU SELECT MONITOR for information about how to obtain and understand the diagnostic trouble code DTC lt Ref to ABS 18 Subaru Select Monitor gt ABS 20 INSPECTION MODE ABS DIAGNOSTICS 8 Inspection Mode A OPERATION Reproduce the condition under which the problem has occurred as much as possible Drive the vehicle at a speed more than 40 km h 25 for at least one minute ABS 21 CLEAR MEMORY MODE ABS DIAGNOSTICS 9 Clear Memory Mode A OPERATION 1 WITHOUT SUBARU SELECT MONITOR 1 After calling up a diagnostic trouble code DTC disconnect the diagnosis connector terminal 6 from diagnosis terminal 1 Diagnosis connector 2 Diagnosis terminals 3 terminal 4 6 terminal 2 Repeat 3 times wit
216. aulic unit nector relay box and ABSCM amp H U CHECK ABSCM amp H U Is the same diagnostic trouble Replace the Go to step 6 ABSCM amp H U Ref to ABS 7 ABS Contro Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code code as in the current diagno sis still being output CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary poor contact ABS 153 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ABS 154 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS AB DTC 52 MOTOR RELAY ON FAILURE DIAGNOSIS Faulty motor e Faulty motor relay e Faulty harness connector TROUBLE SYMPTOM ABS does not operate ABS 155 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY SBF 1 ON D Cc SBF 4 SBF HOLDER IGNITION SWITCH 20 00 00 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SOLENOID VALVE FL INLET FR OUTLET RL INLET RL OUTLET RR INLET RR OUTLE PUMP MOTOR 9 141516 19 24 25 26 29 34 35136 10 20 11112 13 18 21 22 23 28 31 32 33 38
217. ave the valve of pressure gauge closed or hold the steering wheel at stop end for 5 seconds or more in any case as the oil pump may be damaged due to long keep of these conditions e Put cotton cloth waste at a place where fluid drops before pressure gauge is installed Wipe off spilt fluid thoroughly after the measure ment NOTE Keep engine idling during the measurement 1 MEASURE REGULAR PRESSURE 1 Remove the two bolts securing power steer ing pipes to the engine 2 Install ST1 2 and 3 between power steering pump and pipes using gasket Part No 34621AC021 and bolt Part No 34620AC010 3 Replenish the power steering fluid up to specified level 4 Open the valve and start the engine 5 Measure the regular pressure ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE Service limit 981 kPa 10 kg cm 142 psi or less 6 If it is not within the specified value replace the troubled part caused by the following symp toms pipe or hose clogged leaks from fluid line and mix of foreign objects in fluid line 2 Measure relief pressure 1 Using STs measure the relief pressure 2 Close the valve 3 Measure the relief pressure ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099 010 ADAPTER HOSE A Service limit TURBO model 7 350 8 036 kPa 75 82 kg cm 1 067 1 165 psi Non TURBO model 7 164 7 840 kPa 73
218. ber part for creep cracks and deteri oration and replace it with a new one if defective 3 DUST COVER If any cracks or damage are found replace it with a new one 4 COIL SPRING One having permanent strain should be replaced with a new one When the vehicle posture is un even although there are no considerable reasons like tire puncture uneven loading etc check the coil spring for its free length referring to specifica tions cracks etc and replace it with a new one if defective 5 HELPER Replace it with a new one if cracked or damaged F DISPOSAL CAUTION On struts which have GAS FILLED marked on the outer housing under spring seat com pletely discharge the gas before disposing fol lowing the methods below Do not disassemble the strut damper or place into a fire e Drill holes before disposing of gas filled struts Before handling gas filled struts be sure to wear goggles to protect eyes from gas oil and or filings GAS FILLED DO NOT OPEN DO NOT HEAT B4M1201 1 Place the gas filled strut on a flat and level sur face with piston rod fully extended 2 Using a 2 to 3 mm 0 08 to 0 12 in dia drill make holes in areas shown in the figure Piston rod 1 57 in B4M1202A FS 23 FRONT STABILIZER FRONT SUSPENSION 7 Front Stabilizer A REMOVAL 1 Jack up the front part of the vehicle and support it with safety stands rigid racks 2 Remove t
219. bly Keep the disassembled parts in order pro tect them from dust or dirt Before removal installation or disassembly sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part on the vehicle is hot after running e Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or safety stands at the specified points e Apply grease onto sliding or revolution surfaces before installation Before installing O rings or snap rings apply suf ficient amount of grease to avoid damage and de formation e Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice e Keep grease etc away from parking brake shoes PB 5 PARKING BRAKE LEVER PARKING BRAKE 2 Parking Brake Lever 8 Unbend the parking brake lever pawls and move cable A REMOVAL 1 Move the select lever to position or gear shift lever to 1st gear then block the wheels 2 Disconnect the battery ground terminal from bat tery 3 Remove the console box lt Ref to El 41 RE MOVAL Console Box gt 4 Disconnect the connector of parking brake switch 5 Loosen the parking cab
220. boot is installed without un usual inflation or deflation 54 0151 5 36 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 26 Using a screwdriver tighten the screw until the ends A and of the band come into contact with each other CAUTION Use a new band NOTE Always tighten the band from the underside of the gear box PSG NN Xu 27 Fix the boot end with clip small CAUTION After installing check boot end is positioned into groove on tie rod B S4M0152A S4M0144B 1 Clip 28 If the tie rod end was removed screw in lock nut and tie rod end to the screwed portion of tie rod and tighten the lock nut temporarily in a posi tion as shown in figure Installed tie rod length L 15 mm 0 59 in NOTE Pay attention to difference between right and left tie rod ends 29 Install the tie rod end plate Tightening torque 13 N m 1 3 kgf m 9 4 ft lb 30 Inspect the gearbox as follows A Holding tie rod end repeat lock to lock two or three times as quickly as possible B Holding tie rod end turn it slowly at a radius one or two times as large as possible After all make sure that the boot is installed in the specified position without deflation 31 Remove gearbox from ST ST 926200000 STAND 32 Install the four pipes on gearbox 1 Connect the pipe A and B to the four pipe joints of gearbox Tightening torque 1
221. ch on cyl inder inner wall will cause oil leakage 54 0402 1 Rack bushing 2 Rack ASSY 3 Rack stopper PS 30 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 2 CONTROL VALVE 5 Loosen the adjusting screw and remove the 1 Disconnect the four pipes from the gearbox spring and sieeve Remove the pipes E and F as a single unit being Replace the spring and or sleeve If damaged fixed at the clamp plate 6 Remove the two bolts securing valve assembly 2 Secure the gearbox removed from the vehicle in vice using ST ST 926200000 STAND CAUTION Secure the gearbox in a vice using the ST as shown Do not attempt to secure it without this ST 7 Carefully draw out the input shaft and remove the valve assembly 3 Using ST loosen the lock nut ST 926230000 SPANNER 4 Tighten the adjusting screw until it no longer tightens 54 0156 1 Dust cover PS 31 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 9 Using a press remove pinion and valve assem bly from the valve housing 54 0157 1 Valve ASSY 2 Valve housing 3 Cloth 10 Using ST and press remove the dust seal oil seal and special bearing from the valve housing ST 34099FA120 INSTALLER amp REMOVER SEAL CAUTION s Do not apply a force to end surface of valve housing s Do not reuse oil seal after removal 54 0159 1 Oil seal 2 Special bearing 11 Remove the snap rin
222. circuit circuit Select Monitor 26 Rear right ABS sensor Rear right ABS sensor Ref to ABS 110 DTC 26 REAR RIGHT ABNORMAL ABS SEN abnormal signal abnormal signal SOR SIGNAL Diagnostics Chart with Subaru Select Monitor 27 Open or short circuit in Open or short circuit in Ref to ABS 105 DTC 27 OPEN OR SHORT CIRCUIT IN REAR rear left ABS sensor rear left ABS sensor LEFT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru Select circuit circuit Monitor 28 Rear left ABS sensor Rear left ABS sensor lt Ref to ABS 111 DTC 28 REAR LEFT ABNORMAL ABS SENSOR abnormal signal abnormal signal SIGNAL Diagnostics Chart with Subaru Select Monitor gt 29 Abnormal ABS sensor Abnormal ABS sensor lt Ref to ABS 117 DTC 29 ABNORMAL ABS SENSOR SIGNAL signal on any one of signal on any one of ANY ONE OF FOUR SENSOR Diagnostics Chart with Subaru four sensor four Select Monitor gt malfunction malfunction FUNCTION Diagnostics Chart with Subaru Select Monitor gt Front right outlet valve Front right outlet valve lt Ref to ABS 125 DTC 32 FRONT RIGHT OUTLET VALVE MAL malfunction malfunction FUNCTION Diagnostics Chart with Subaru Select Monitor gt Front left inlet valve Front left inlet valve lt Ref to ABS 121 DTC 33 FRONT LEFT INLET VALVE MALFUNC Front left outlet valve Front left outlet valve lt Ref to ABS 125 DTC 34 FRONT LEFT OUTLET VALVE MAL malfunction malfunction FUNCTION Diagnosti
223. corre contact sponding to the diagnostic trouble code ABS 146 TU War ETE A pA e m mn ns ue 55 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Z DTC 51 VALVE RELAY ON FAILURE DIAGNOSIS e Faulty valve relay TROUBLE SYMPTOM ABS does not operate ABS 147 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY SBF 3 SBF 1 a SBF 4 8 IGNITION SWITCH ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SOLENOID VALVE FL_INLET FL OUTLET FR INLET FR OUTLET RL INLET RL OUTLET RR RR OUTLE PUMP MOTOR 1121314 r1 5 6 7 8 9 tojni jieji 14 15 16 17 18 19 20 9 BiG toj t7 19 27 17 18 7 0087 5 148 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK VALVE RELAY IN ABSCM amp H U Measure the resistance between ABSCM amp H U terminals Terminals No 23 No 24 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE s the resistance more than 1 MQ Is there poor contact con nectors between generator battery and ABSCM amp H U Is the same diagnostic trouble code as in the c
224. correct direction as shown in the figure S4M0351A 1 Face bushing toward center of ball joint 2 Ball joint 2 REAR BUSHING 1 Install the rear bushing to transverse link and align the aligning marks scribed on the two 2 Tighten the self locking nut CAUTION Discard the loosened self locking nut and re place with a new one e While holding the rear bushing so as not to change position of aligning marks tighten the self locking nut Tightening torque 190 N m 19 4 kgf m 140 ft lb E INSPECTION 1 Check the transverse link for wear damage and cracks and correct or replace if defective 2 Check the bushings for cracks fatigue or dam age 3 Check the rear bushing for oil leaks FS 18 FRONT BALL JOINT FRONT SUSPENSION 5 Front Ball Joint A REMOVAL 1 Remove the front wheel 2 Pull out the cotter pin from the ball stud remove the castle nut and extract the ball stud from the transverse link 3 Remove the bolt securing the ball joint to the housing 4 Extract the ball joint from the housing B INSTALLATION 1 Install the ball joint onto the housing Torque Bolt 50 5 1 kgf m 37 ft lb CAUTION Do not apply grease to the tapered portion of ball stud 2 Connect the ball joint to transverse link Torque Castle nut Sedan turbo model 30 N m 3 1 kgf m 22ft Ib Except sedan turbo model 45 N m 4 6 kgf m 33ft Ib 3 Retighten the castle nut furthe
225. creen select the Brake Control System and press the YES key 3 Press the YES key after displayed the information of ABS type 4 On the Brake Control Diagnosis display screen select the Current Data Display amp Save and press the YES key 5 On the Data Display Menu display screen select the Data Display and press the YES key 6 Using the scroll key move the display screen up or down until the desired data is shown A list of the support data is shown in the following table Display screen FR Wheel Speed FL Wheel Speed RR Wheel Speed RL Wheel Speed Contents to be monitored heel speed detected by the Front Right ABS sensor is displayed heel speed detected by the Front Left ABS sensor is displayed heel speed detected by the Rear Right ABS sensor is displayed heel speed detected by the Rear Left ABS sensor is displayed Stop Light Switch Stop light switch signal ON or OFF Stop Light Switch Stop light switch monitor voltage is displayed G sensor output Signal Refers to vehicle acceleration detecting by the analog G sensor It appears on the select monitor display volts Valve Relay Signal ON or OFF Motor Relay Signal ON or OFF ABS operation signal from ABS control module to ON or OFF ON operation of the ABS warning light is displayed ON or OFF Operating condition of the motor relay is displayed ON or OFF Operating condition of the valve relay is d
226. cs Chart with Subaru Select Monitor gt Rear right inlet valve Rear right inlet valve lt Ref to ABS 121 DTC 35 REAR RIGHT INLET VALVE MALFUNC 32 33 34 35 6 3 Rear right outlet valve Rear right outlet valve Ref to ABS 125 DTC 36 REAR RIGHT OUTLET VALVE MAL malfunction malfunction FUNCTION Diagnostics Chart with Subaru Select Monitor gt 37 Rear left inlet valve Rear left inlet valve lt Ref to ABS 121 DTC 37 REAR LEFT INLET VALVE MALFUNC malfunction malfunction TION Diagnostics Chart with Subaru Select Monitor gt 38 Rear left outlet valve Rear left outlet valve Ref to ABS 125 DTC 38 REAR LEFT OUTLET VALVE MALFUNC malfunction malfunction TION Diagnostics Chart with Subaru Select Monitor ABS control module ABS control module to ABS 130 DTC 41 ABS CONTROL MODULE MALFUNC Um malfunction ano TION Diagnostics Chart with Subaru Select Monitor gt unit malfunction Power supply voltage Power supply voltage Ref to ABS 132 42 POWER SUPPLY VOLTAGE TOO LOW too low too low Diagnostics Chart with Subaru Select Monitor gt Power supply voltage Power supply voltage lt Ref to ABS 134 DTC 42 POWER SUPPLY VOLTAGE TOO HIGH too high too high Diagnostics Chart with Subaru Select Monitor gt ABS 26 42 2 4 LIST OF DIAGNOSTICS TROUBLE CODE DTC ABS DIAGNOSTICS 44 ABS AT contro Non ABS AT control Non Ref to ABS 138 DTC 44 ABS AT CONTROL
227. d ST2 remove the hub from the rear housing ST 927080000 ST 927420000 HUB STAND HUB REMOVER 2 Remove the back plate from the rear housing 3 Using a standard screwdriver remove the outer and inner oil seals CAUTION Use new oil seals 4 Using flat bladed screwdriver remove the snap ring CAUTION Be careful not to damage housing at removal 5 Using ST1 and ST2 remove the bearing by pressing inner race ST1 927430000 HOUSING STAND ST2 927440000 BEARING REMOVER CAUTION Do not remove bearing unless damaged Do not re use bearing after removal DS 28 REAR AXLE 6 Remove the tone wheel bolts and remove the tone wheel from the hub only vehicle equipped with ABS 7 Using ST press the hub bolt out ST 927080000 HUB STAND CAUTION careful not to hammer the hub bolts This may deform hub DRIVE SHAFT SYSTEM D ASSEMBLY 1 Using ST press the new hub bolt into place CAUTION Ensure hub bolt closely contacts hub e Use a 12 mm 0 47 in hole in the ST to pre vent hub bolt from tilting during installation ST 927080000 HUB STAND 2 Remove the foreign particles dust rust etc from the mating surfaces of hub tone wheel and in stall the tone wheel to hub only vehicle equipped with ABS CAUTION e Ensure tone wheel closely contacts hub Be careful not to damage tone wheel teeth 54 0370 1 Tone wheel DS 29 REAR AXLE DRIVE SHAFT
228. d left brake assembly at the same time D ADJUSTMENT 1 SHOE CLEARANCE 1 Remove the adjusting hole cover from back plate 2 Turn the adjusting screw using a slot type screw driver until the brake shoe is in close contact with disc rotor S4M0463A 1 Adjusting screw 2 Cover rubber 3 Slot type screwdriver 4 Back plate 3 Turn back downward the adjusting screw 3 or 4 notches 4 Install the adjusting hole cover to back plate 2 LEVER STROKE 1 Remove the console box lid 2 Forcibly pull the parking brake lever 3 to 5 times 3 Adjust the parking brake lever by turning adjust er until the parking brake lever stroke is set at 6 notches with operating force of 196 N 20 kof 44 Ib 1 Parking brake lever 2 Lock nut 3 Adjusting nut 4 Tighten the lock nut 5 Install the console box lid Lever stroke 7 to 8 notches when pulled with a force of 196 N 20 kof 44 Ib Tightening torque Adjuster lock nut 6 0 6 kgf m 4 4 ft lb PB 12 GENERAL DIAGNOSTIC TABLE PARKING BRAKE 5 General Diagnostic Table A INSPECTION 13 GENERAL DIAGNOSTIC TABLE PARKING BRAKE PB 14 POWER ASSISTED SYSTEM POWER STEERING Page 1 General DESCHONON owed beata 2 NEMPE Rl 19 Se 15 55 2 6 T Es 20 4
229. de gear and pinion mate gear e Replace if crack score or other defects are evi dent on tooth surface e Heplace if thrust washer contacting surface is worn or seized Slight damage of the surface can be corrected by oil stone or the like 3 Bearing Replace if seizure peeling wear rust dragging during rotation abnormal noise or other defect is evident 4 Thrust washers of side gear and pinion mate gear Replace if seizure flaw abnormal wear or other defect is evident 5 seal Replace if deformed or damaged and at every dis assembling 6 Differential carrier Replace if the bearing bores are worn or damaged 7 Differential case Replace if its sliding surfaces are worn or cracked 8 Companion flange Replace if the oil seal lip contacting surfaces have flaws 1 SIDE GEAR BACKLASH Using a dial gauge check the backlash of the side gear Side gear backlash 0 1 0 2 mm 0 004 0 008 in If the side gear backlash is not within the specifica tion adjust clearance as specified by selecting side gear thrust washer 2 CROWN GEAR BACKLASH Using a dial gauge check the backlash of the crown gear Crown gear backlash 0 1 0 2 mm 0 004 0 008 in If the crown gear backlash is not within the specifi cation adjust the side bearing preload or repair if necessary DI 33 REAR DIFFERENTIAL DIFFERENTIALS 3 CROWN GEAR RUNOUT Using a dial gauge check the crown gear runo
230. display CHECK OUTPUT OF G SENSOR USING SE 15 the sensor output on the LECT MONITOR monitor display between 3 7 1 Turn the ignition switch to OFF and 4 1 V when G sensor is 2 Remove the console box inclined forwards to 90 3 Remove the G sensor from vehicle Do not disconnect connector 4 Turn the ignition switch to ON 5 Select Current data display amp Save on the select monitor 6 Read the select monitor display CHECK OUTPUT SENSOR USING SE 5 the sensor output on the LECT MONITOR monitor display between 0 5 Read the select monitor display and 0 9 V when G sensor is inclined backwards to 90 CHECK POOR CONTACT IN CONNECTORS 15 there poor contact con Turn the ignition switch to OFF nector between ABSCM amp H U and G sensor Is the same diagnostic trouble code as in the current diagno sis still being output Replace the G sensor Hef to ABS 23 G Sen Sor Go to step 6 Go to step 5 Repair the con nector CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code Replace the Go to step 7 ABSCM amp H U lt Ref to ABS 7 ABS Control ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code Go to step 9 Go to step 10
231. djustment Type Effective diameter Reservoir type Brake fluid reservoir capacity Type Effective diameter Tandem 26 99 mm 1 1 16 in Sealed type 205 cm 12 51 cu in Vacuum suspended 205 230 mm 8 07 9 06 in 1 961 kPa 20 kg cm 285 psi 0 3 Dual circuit system FMVSS No 116 DOTS DOT4 Master cylinder Brake booster Proportioning Split point valve Reducing ratio Brake line Brake fluid NOTE Refer to PB section for parking brake SPECIFICATIONS lt Ref to PB 2 SPECIFICATIONS General De scription gt BR 2 GENERAL DESCRIPTION BRAKE ITEM STANDARD SERVICE LIMIT Pad thickness including back metal 17 mm 0 571 in 7 5 mm 0 295 in 24 mm 0 94 in 22 mm 0 87 in 075 0 0080 in Pad thickness including back metal 14 mm 0 55 in 6 5 mm 0 256 in ear brake Disc type 10 mm 0 39 in 8 5 mm 0 335 in Dermot 997mm 00028 Inside diameter 228 6 mm 9 in 230 6 mm 9 08 in arn rer Inside diameter Lining thickness 4 1 mm 0 161 in 1 5 mm 0 059 in inside diameter 170 mm 6 69 in 171 mm 6 73 in rake Disc type parking ning thickness 3 2 mm 0 126 in 1 5 mm 0 059 in Parking brake 7 to 8 notches 196 N 20 kgf 44 Ib Fluid pressure 147 588 kPa 294 1 471 Brake fluid pressure without engine running Brake booster Brake fluid i
232. e Do not disconnect connector 3 Read the select monitor display CHECK G SENSOR Read the select monitor display Check Do you have the SUBARU SELECT MONITOR Is the voltage 2 3 0 2 V when G sensor is horizontal Go to step 3 Is the voltage 3 9 0 2 V when G sensor is inclined forwards to 90 Is the voltage 0 7 0 2 V when G sensor is nor G sensor is inclined backwards mal Is the indicated reading Go to step 6 2 3 0 2 V when the vehicle is in horizontal position Is the indicated reading Go to step 7 3 9 0 2 V when G sensor is inclined forwards to 90 G sensor is nor mal Is the indicated reading 0 70 2 V when sensor is inclined backwards to 90 ABS 24 We _ Go to step 5 Go to step 2 Replace G sensor Replace G sensor Replace G sensor Replace G sensor Replace G sensor Replace G sensor ABS DIAGNOSTICS gt ae 00 I ce ed Basic 0 51 Check EISETOF Inter Vie Wu Electrical Components EoGalloni cei Control Module VO SIGH Al ied ursa ieee bake eaae ER cubat Subaru elect Montor Feet coca dit do vor enea
233. e HOLDER E E 3114 9 45 16 19 24 25 26 29 10 11112113 18 2122129 28 31 32 33 38 2108 0085 5 70 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Step Check Yes No CHECK GENERATOR 5 the voltage between 10 and to step 2 Repair the genera 1 Start the engine 7V or Ref to SC 2 ldling after warm up 13 Generator 3 Measure the voltage between generator B terminal and chassis ground Terminal Generator B terminal Chassis ground CHECK BATTERY TERMINAL the positive and negative to step 3 Tighten the clamp Turn the ignition switch to OFF iattery terminals tightly f terminal lamped CHECK INPUT VOLTAGE OF RELAY HOLD 5 the voltage more than 10 V 30 to step 4 Repair open circuit ER n harness 1 Turn the ignition switch to OFF oetween battery 2 Remove the fuse Relay holder 3 Measure the voltage between ABS relay connector connector and chassis ground Connector amp terminal B225 5 Chassis ground CHECK RELAY HOLDER 5 the fuse blown out Replace the fuse Go to step 5 CHECK INPUT VOLTAGE OF ABS RELAY 5 the voltage more than 10 V to step 6 Hepair open circuit 1 Instali the fuse in harness 2 Remove the ABS relay between battery 3 Turn the ignition switch to ON and Relay holder 4 Measure the voltage between ABS relay connector connector and chassis
234. e front 54 0461 1 LEFT PARKING BRAKE NOTE Ensure that the shoe return spring is installed as shown in Figure 54 0462 1 Back plate 2 Shoe guide plate 3 Retainer 4 Spring washer 5 Lever 6 Primary shoe return spring Blue 7 Secondary shoe return spring Yellow 8 Parking brake shoe Primary 9 Parking brake shoe Secondary 3 Adjust the parking brakes lt Ref to PB 12 AD JUSTMENT Parking Brake Assembly Rear Disc Brake gt CAUTION After replacing the parking brake lining be sure to drive the vehicle for break in purposes 1 Drive the vehicle at about 35 km h 22 MPH 2 With the parking brake release button pushed in pull the parking brake lever gently 3 Drive the vehicle for about 200 meter 0 12 mile in this condition 4 Wait 5 to 10 minutes for the parking brake to down Repeat this procedure once more 5 After breaking in re adjust the parking brakes PB 11 PARKING BRAKE ASSEMBLY REAR DISC BRAKE PARKING BRAKE C INSPECTION 1 Measure the brake disc inside diameter If the disc is scored or worn replace the brake disc Disc inside diameter Standard 170 mm 6 69 Service limit 171 mm 6 73 in 2 Measure the lining thickness If it exceeds the limit replace shoe assembly Lining thickness Standard 3 2 mm 0 126 in Service limit 1 5 mm 0 059 CAUTION Replace the brake shoes on the right an
235. e RL and RR caliper bodies 12 Bleed air from the pressure gauges and the FL and FR caliper bodies 13 Perform the ABS sequence control lt Ref to ABS 11 ABS Sequence Control gt 14 When the hydraulic unit begins to work at first the RR side performs decompression holding and compression and then the RL side performs de compression holding and compression 15 Read the values indicated on the pressure gauges and check if they meet the standard value 16 After checking remove the pressure gauges from caliper bodies 17 Connect the air bleeder screws to RL and RR caliper bodies 18 Bleed air from the brake line 2 CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH BRAKE TESTER 1 In the case of AWD AT Non turbo vehicles in stall a spare fuse with the FWD connector in the main fuse box to simulate FWD vehicles El MS eL EY PL U 7 1 Main fuse box 2 FWD connector 2 Prepare for operating the ABS sequence control lt Ref to ABS 11 ABS Sequence Control gt 3 Set the front wheels or rear wheels on the brake tester and set the select lever s position at neu tral yO 1 B4M1733B 1 B4M1730B 1 Brake tester 4 Operate the brake tester 5 Perform ABS sequence control lt Ref to ABS 11 ABS Sequence Control gt ABS 9 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT ABSCM amp H U ABS 6 Hydraulic unit begins to work and c
236. e between 4 75 and 5 25 V Measure the voltage between G sensor con 4 1 V when G sensor is sensor lt Ref to nector terminals inclined forwards to 90 ABS 23 G Sen Connector amp terminal sor gt B292 No 2 No 3 CHECK G SENSOR Measure the voltage between sensor nector terminals Connector amp terminal B292 No 2 No 3 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR CHECK POOR CONTACT IN CONNECTORS Turn the ignition switch to OFF CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Is there poor contact in con nector between ABSCM amp H U and G sensor Is the same diagnostic trouble code as in the current diagno sis still being output Are other diagnostic trouble codes being output ABS 173 ABS DIAGNOSTICS Hepair the con nector Go to step 22 Replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code Go to step 23 A temporary poor contact DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ABS 174 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS AG DTC 56 ABNORMAL SENSOR HIG
237. e cable bracket only vehicle equipped with ABS 4 1139 1 ABS sensor 10 Bleed air from brake system lt Ref to BR 44 REPLACEMENT Brake Fluid gt 11 Adjust the parking brake lever stroke by turning adjuster 12 Move the brake lever back to apply brakes While depressing brake pedal tighten the axle nut using a socket wrench Lock the axle nut after tight ening Tightening torque 186 19 kgf m 137 ft lb CAUTION e Use a new axle nut Always tighten axle nut before installing wheel on vehicle If wheel is installed and comes in contact with ground when axle nut is loose wheel bearings may be damaged Be sure to tighten axle nut to specified torque Do not overtighten it as this may dam age wheel bearing 13 Install the wheel and tighten the wheel nuts to specified torque Tightening torque 88 N m 9 kgf m 65 ft lb 2 DRUM BRAKE 1 Connect the rear housing assembly and strut as sembly CAUTION Use a new self locking nut Tightening torque 196 N m 20 kgf m 145 ft Ib 2 Fit the BJ bell joint to rear housing splines CAUTION Be careful not to damage inner oil seal lip 3 Connect the rear housing assembly to the lateral link assembly CAUTION Use a new self locking nut Tightening torque 137 N m 14 kgf m 101 ft Ib 4 Connect the rear housing assembly to the trail ing link assembly CAUTION Use a new self locking nut Tightening torque 113
238. e of relief status Replace Instruct customer Excessive tightening torque for return hose clip Crack on hose Power steering fluid brake fluid engine oil electro Replace lyte adhere on the hose surface Pay attention on service work Replace Instruct customers Improper stop position of pitching stopper Replace defective parts Too many times use in extremely cold weather PS 52 PIPE ASSEMBLY POWER ASSISTED SYSTEM POWER STEERING CAUTION It is likely that although one judges fluid leakage there is actually no leakage This is because the flu id spilt during the last maintenance was not completely wiped off Be sure to wipe off spilt fluid thor oughly after maintenance 16 18 11 17 20 4 L 7 Y oi tle BOX lt 27 ey 8 6 T I 13 10014 PS 53 PIPE ASSEMBLY POWER ASSISTED SYSTEM POWER STEERING Fluid leaking area Possible cause Corrective action Insufficient tightening of flare nut catching dirt or the like damage to flare or flare nut or Leakage from connecting portions of eye bolt pipes and hoses numbered with 1 through 10 in figure Replace O ring or gasket pipe or hose Damaged O ring or gasket with new one if ineffective replace the gearbox also Leakage from hose 11 12 and Crack or damage in hose Replace with a new one 13 in figure Crack or damage in hose hardware Replace with a new one Loose
239. e properly adjusted and have no defects Hydraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of combined conditions i e road surface and tire surface engine speed and turning speed of steering wheel fluid temperature and braking con dition This phenomena does not indicate there is some abnormal function in the system The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step with parking brake applied on concrete road and in D range for automatic trans mission vehicle PS 75 GENERAL DIAGNOSTIC TABLE POWER ASSISTED SYSTEM POWER STEERING Trouble Possible cause Corrective action Relief valve emits operating sound when steering wheel is completely turned in either direction Don t keep this con dition over 5 seconds Relief valve emits operating sound when steering wheel is Defective not turned This means that the relief valve is faulty Heplace the oil pump Check the clearance Correct if necessary Ref to PS 52 INSPECTION Pipe Assembly Loosened installation of oil pump tank pump bracket Rattling noise intermittent gearbox or crossmember Retighten While engine is running Loosened installation of oil pump pulley or other pulley s Retighten Normal Hiss noise continuous While engine is running Interference with adjacent pa
240. e rear drive shaft to rear crossmem ber using wire NU oe T Vy 9 jack DI 19 REAR DIFFERENTIAL DIFFERENTIALS 18 Remove the self locking nuts and bolts 22 Remove the rear differential from front mem ber and remove rear member M 19 Remove the bolts which secure rear differential front member to body B INSTALLATION Loosen bolt A first then remove bolts B To install reverse the removal sequence NOTE 1 Install the air breather cap tapping with a plastic Support the front member with the use of a helper hammer to prevent it from dropping CAUTION Be sure to install a new air breather cap 2 Position the front member on body by passing it under parking brake cable and securing to rear dif ferential NOTE When installing the rear differential front member do not confuse the installation sequence of the up per and lower stoppers 3 Install the DOJ of drive shaft into rear differen B3M0657C tial lt Ref to DI 37 REPLACEMENT Rear Differ ential Side Oil Seal gt A BoltA ST 28099PA090 SIDE OIL SEAL PROTEC BoltB TOR 20 Remove bolt A 21 While siowly lowering the transmission jack move rear differential forward and remove front member and rear differential from body 4 Install in the reverse order of removal 5 After installation fill the differential carrier with gear
241. e the nut of protector by using ST ST 398527700 PULLER ASSY CAUTION When removing the DOJ from the rear differen tial fit ST to the bolts as shown in figure 50 as not to damage the side bearing retainer ST 208099PA100 DRIVE SHAFT REMOVER G3M1023 11 Drive in a new side oil seal with ST CAUTION Apply chassis grease between the oil seal lips ST 398437700 DRIFT iiie 12 Insert the DOJ into rear differential A Bolt 1 Install the ST to rear differential ST 28099 090 SIDE OIL SEAL PROTEC 9 Remove the rear drive shaft to rear crossmem TOR ber using wire air wC as Q2 NS 15 9 DI 38 REAR DIFFERENTIAL SIDE OIL SEAL DIFFERENTIALS 2 Install the spline shaft until the spline portion is inside the side oil seal using ST ST 28099PA090 SIDE OIL SEAL PROTEC TOR Bia os o 522 j G3M1026 3 5 ST 28099PA090 SIDE OIL SEAL PROTEC TOR 13 Hereafter reassemble in the reverse order of disassembly 14 Fill differential carrier with gear oil to the filler plug level Ref to 01 17 Differential Gear Oil DI 39 REAR DIFFERENTIAL MEMBER DIFFERENTIALS 7 Rear Differential Member A REMOVAL 1 Set the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Move the selector lever or gear shift lever to 4 Release the parking brake 5 Loosen the wheel nuts 6 Jack up the vehicle
242. e the shoes one by one from back plate with adjuster CAUTION Be careful not to bend the parking brake cable excessively when removing the brake shoes Wheel cylinder Adjuster Back plate Lower shoe return spring Parking lever G4M0397 8 Disconnect the parking brake cable from parking lever BR 30 REAR DRUM BRAKE SHOE BRAKE INSTALLATION 1 Clean the back plate and wheel cylinder 2 Apply grease to the portions indicated by arrows in the figure Brake grease Dow Corning Molykote No 7439 Part No 725191460 3 Apply grease to the adjusting screw and both ends of adjuster Brake grease Dow Corning Molykote No 7439 Part No 725191460 4 Connect the upper shoe return spring to shoes 5 Connect the parking brake cable to parking le ver 6 While positioning the shoes one at a time in groove on wheel cylinder secure shoes 7 Fix the shoes by connecting hold down cup to hold down pin 8 Connect the lower shoe return spring 9 Set the outside diameter of brake shoes less than 0 5 to 0 8 mm 0 020 to 0 031 in in compari son with the inside diameter of brake drum 10 Install the drum lt Ref to BR 32 INSTALLA TION Rear Drum Brake Drum gt C INSPECTION 1 Measure the lining thickness Lining thickness Standard 4 1 mm 0 161 in Service limit 1 5 mm 0 059 in 2 If the deformation or wear of back plate shoe etc are notable replace them
243. e tone wheel to ABS sensor piece gap over entire perimeter of the wheel jolts tightened securely 5 the gap within the specifica ions 30 to step 4 Adjust the gap NOTE Adjust the gap us Front wheel ing spacers Pai 0 3 0 8 mm 0 012 0 031 in 26755AA000 Rear wheel If spacers cannc 0 7 1 2 mm 0 028 0 047 in correct the gap re place the wor sensor or wor tone wheel 3o to step 5 Replace the tone wheel Front Ref to ABS 21 Front Tone Wheel Rear Ref to ABS 22 Rear Tone Wheel Go to step 6 TONE WHEEL RUNOUT Measure the tone wheel runout s the runout less than 0 05 nm 0 0020 in CHECK POOR CONTACT IN CONNECTORS Turn the ignition switch to OFF iepair the con vector s there poor contact in con iectors between ABSCM amp H U ind ABS sensor S the same diagnostic trouble ode as in the current diagno iis still being output CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code Replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod and Hydraulic contro Unit ABSCM amp H U gt roceed with the liagnosis corre sponding to the fiagnostic trouble Go to step 7 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagn
244. e wheel bearings 5 Remove the stabilizer link from the transverse link 6 Disconnect the transverse link from the housing 7 Remove the spring pin which secures transmis sion spindle to SFu CAUTION Use a new spring pin 8 Remove the front drive shaft assembly If it is hard to remove use ST1 and ST2 ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXLE SHAFT PULLER PLATE CAUTION e Be careful not to damage the oil seal lip and tone wheel when removing front drive shaft e When front drive shaft is to be replaced also replace inner oil seal B INSTALLATION 1 Insert the BJ into hub splines CAUTION Be careful not to damage inner oil seal lip and tone wheel 2 Using ST1 and ST2 pull the drive shaft into place ST1 922431000 AXLE SHAFT INSTALLER ST2 927390000 ADAPTER CAUTION Do not hammer drive shaft when installing it 3 Tighten the axle nut temporarily 4 Install the SFJ on transmission spindle and drive spring pin into place CAUTION Always use a new spring pin 5 Connect the transverse link to the housing Tightening torque self locking nut 49 5 0 kgf m 36 ft lb CAUTION Use a new self locking nut 6 Install the stabilizer bracket DS 32 FRONT DRIVE SHAFT 7 While depressing brake pedal tighten the axle nut to the specified torque Tightening torque 186 19 kgf m 137 ft lb CAUTION e Use a new axle nut e Always tighten axle nut befo
245. eck specifications of the mark to the and the ABSCM amp H U specifi ABSCM amp H U ABSCM amp H U cation match Ref to ABS 7 CC AT ABS Control Mod CD MT ule and Hydraulic Control Unit ABSCM amp H U CAUTION Be sure to turn ig nition switch to OFF when remov ing ABSCM amp H U Go to step 4 Repair harness connector between G sensor and ABSCM amp H U Is the resistance between 4 3 to step 5 Repair harness and 4 9 connector between G sensor ABSCM amp H U Is the resistance more than 1 to step 6 Repair harness MQ between G sensor Go to step 7 and ABSCM amp H U Go to step 8 CHECK INPUT VOLTAGE OF G SENSOR 1 Turn the ignition switch to OFF 2 Remove the console box 3 Disconnect the G sensor from body Do not disconnect the connector 4 Turn the ignition switch to ON 5 Measure the voltage between G sensor con nector terminals Connector amp terminal B292 1 No 3 CHECK OPEN CIRCUIT IN G SENSOR OUT PUT HARNESS AND GROUND HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp 3 Measure the resistance between ABSCM amp H U connector terminals Connector amp terminal F49 No 6 No 28 CHECK GROUND SHORT IN G SENSOR OUTPUT HARNESS 1 Disconnect the connector from G sensor 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal
246. ed to it onto the connector and secure connector to the front casing CAUTION e Use care to prevent damage to O ring at in stallation When tightening the connector ensure that the O ring does not protrude or get caught Tightening torque 49 N m 5 0 kgf m 36 2 ft lb 1 1 Flow control spring 2 Spool valve assembly 3 4 3 4 O ring Connector 18 Fix the oil pump pulley temporarily 19 When the reassembly procedures have been completed turn the shaft by hand to ensure it turns smoothly If it binds or other unusual conditions evident disassemble again and check for foreign matter trapped on sliding surfaces and improper in stallation Eliminate the cause of trouble 20 Check followings by referring to CHECK arti cle e Excessive play in pulley shaft e Ditch deflection of pulley Resistance to rotation of pulley Measurement of generated oil pressure 2 TURBO MODEL 1 Reassembly precautions 1 Whenever the O rings oil seals and snap rings are removed they must be replaced with new ones 2 Thoroughly wash the parts and allow to dry They must be kept free from cleaning oil and dust 3 Reassembly procedure must be performed in clean place Ensure that the parts are kept away from the waste threads or other dust parti cles 4 Cleaning oil tends to stay inside the front casing Remove it completely by blowing com pressed air b Ensure that the parts are free
247. eel gt Set the steering wheel to neutral and install it onto steering shaft CAUTION Insert roll connector guide pin into guide hole on lower end of surface of steering wheel to prevent damage Draw out airbag system con nector horn connector and cruise control con nectors from guide hole of steering wheel lower end 11 Install the airbag module to the steering wheel WARNING Always refer to Air Bag System before per forming the service operation lt Ref to AB 12 CAUTION Driver s Airbag Module gt E INSPECTION 1 BASIC INSPECTION POWER ASSISTED SYSTEM POWER STEERING C DISASSEMBLY Remove the two screws securing upper steering column covers and the two screws securing com bination switch then remove the related parts ASSEMBLY 1 Insert the combination switch to the upper col umn shaft and install the upper column cover Then route the ignition key harness and combina tion switch harness between column cover mount ing bosses Tightening torque 1 2 N m 0 12 kgf m 0 9 ft lb CAUTION Don t overtorque the screw Clean the disassembled parts with cloth and check for wear damage or any other faults If necessary re pair or replace faulty parts e Overall length of steering column Measure overall length of steering column Standard overall length of steering column 825 7 1 5 32 51 0 059 2 AIRBAG MODEL INSPECTION WARNING For airbag model inspection
248. eload for front and rear bearings Adjust the bearing preload with spacer and washer between front and rear bearings Pinion height ad justing washer are not affected by this adjustment The adjustment must be carried out without oil seal inserted 1 Press the rear bearing race into differential carrier with ST1 and ST2 ST1 398477701 HANDLE ST2 398477703 DRIFT 2 2 Insert the ST1 into carrier with pinion height adjusting washer and rear bearing cone fitted onto it CAUTION e Re use the used washer if not deformed e Use a new rear bearing cone DI 24 REAR DIFFERENTIAL 3 Then install the preload adjusting spacer and washer front bearing cone ST2 compan ion flange and washer and drive pinion nut ST1 398507702 DUMMY SHAFT ST2 398507703 DUMMY COLLAR S3M0516A A Pinion height adjusting shim Preload adjusting spacer Preload adjusting washer 4 Turn the ST1 with hand to make it seated and tighten the drive pinion nut while measuring the preload with spring balance Select the pre load adjusting washer and spacer so that the specified preload is obtained when nut is tight ened to the specified torque CAUTION Use a new lock nut NOTE Be careful not to give excessive preload When tightening the drive pinion nut lock ST1 with ST2 as shown in the figure ST1 398507704 BLOCK ST2 398507702 DUMMY SHAFT Tightening torque 181 18 5 kgf m 134 ft lb DIFFERENTIALS
249. entering the hose and pipe cover the open ends of them with a clean cloth 1 Suction hose 2 6 Remove the bolts which install power steering pump bracket B2M3151 7 Place the oil pump bracket in a vise remove the two bolts from the front side of oil pump CAUTION Do not place oil pump bracket directly in the vise use soft pads and hold oil pump lightly to protect the pump 8 Remove the bolt from the rear side of oil pump 9 Disassemble the oil pump and bracket by insert ing a screwdriver as shown in the figure PS 56 INSTALLATION 1 NON TURBO MODEL 1 Install the oil pump to the bracket 1 Place the oil pump bracket in a vise Tighten the bushing using a 12 7 mm 1 2 type 14 and 21 mm box wrench until it is in contact with oil pump mounting surface CAUTION Do not place oil pump bracket directly in the vise use soft pads and hold oil pump lightly to protect the pump B4M1670B 1 Bush 2 Nut 3 21mm 4 14mm 5 Bolt 2 Tighten the bolt which installs oil pump to the bracket Tightening torque 15 7 1 6 kgf m 11 6 ft lb POWER ASSISTED SYSTEM POWER STEERING Tightening torque 37 3 3 8 kgf m 27 5 ft lb 2 Tighten the bolt which installs power steering pump bracket Tightening torque 22 2 2 kgf m 15 9 ft lb 3 Interconnect the pipe C and suction hose Tightening torque Joint nut 3
250. er cable for damage bends and NOTE e Be sure to pass the cable through the cable guide inside tunnel Be sure to adjust the lever stroke lt Ref to PB 7 Cracks ADJUSTMENT Parking Brake Lever gt 4 Check the boot for damage cracks and deterio ration PB 9 PARKING BRAKE ASSEMBLY REAR DISC BRAKE PARKING BRAKE 4 Parking Brake Assembly Rear Disc Brake A REMOVAL 1 Set the vehicle on a lift 2 Disconnect the ground terminal from battery 3 Loosen the wheel nuts 4 Jack up the vehicle and remove wheel 5 Remove the two mounting bolts and remove the disc brake assembly x AAS jdm 1 Disc brake ASSY wr ry c y G4M0459A 6 Suspend the disc brake assembly so that the hose is not stretched 7 Pull down and release the parking brake 8 Remove the disc rotor NOTE If the disc rotor is difficult to remove try the following two methods in order 1 the adjusting screw using a slot type screwdriver until the brake shoe gets away enough from the disc rotor 54 0569 1 Adjusting screw 2 Cover rubber 3 Slot type screwdriver 4 Back plate 2 If the disc rotor seizes up within the hub drive the disc rotor out by installing an 8 mm bolt in holes B on the rotor 9 Remove the primary and secondary return spring from parking brake assembly 10 Remove the
251. er diagnostic trouble odes being output HECK FREEZE FRAME DATA 1 Select Freeze frame data on the select monitor 2 Read the front right wheel speed on the select monitor display CHECK FREEZE FRAME DATA Read the front left wheel speed on the select monitor display CHECK FREEZE FRAME DATA Read the rear right wheel speed on the select monitor display CHECK FREEZE FRAME DATA Read the rear left wheel speed on the select monitor display CHECK FREEZE FRAME DATA Read the G sensor output on the select moni tor display CHECK OPEN CIRCUIT IN G SENSOR OUT PUT HARNESS AND GROUND HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Measure the resistance between ABSCM amp H U connector terminals Connector amp terminal F49 No 6 No 28 CHECK BATTERY SHORT OF HARNESS 1 Turn the ignition switch to OFF 2 Remove the console box 3 Disconnect the connector from G sensor 4 Disconnect the connector from ABSCM amp H U 5 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 6 Chassis ground 5 the front right wheel speed monitor display 0 km 5 the front left wheel speed on nonitor display 0 km 5 the rear right wheel speed monitor display km 5 the rear left wheel speed nonitor display 0 km
252. esis TOOTH CONTACT PATTERN tance when differential case is not installed if NOTE the increase of the resistance is not within the specified range readjust side bearing retainer shims Be sure to wipe off red lead completely after adjust ment is completed Turning resistance increase 2 9 10 8 0 3 1 1 kgf 0 7 2 4 Ib DI 30 REAR DIFFERENTIAL DIFFERENTIALS 18 If proper tooth contact is not obtained once Where again adjust the drive pinion height changing RH T Thickness of pinion height adjusting shim and LH side bearing retainer shims and the hypoid mm gear backlash To Thickness of shim temporarily inserted 1 Drive pinion height mm ST1 398507702 DUMMY SHAFT N Reading of thickness gauge mm ST2 398507701 DIFFERENTIAL CARRIER H Figure marked on drive pinion head GAUGE 2 Hypoid gear backlash Backlash 0 10 0 20 mm 0 0039 0 0079 in H3M1309B T N Hx 0 01 0 20 mm TOOTH CONTACT PATTERN Condition Contact pattern Adjustment Correct tooth contact Tooth contact pattern slightly shifted towards toe under no load rotation When loaded contact pattern moves toward heel Toe side Heel side G3M0098A Face contact This may cause noise and chipping at Increase thickness of drive pinion height Backlash is too large tooth ends adjusting shim in order to bring drive pin ion closer to crown gear center G3M0098B G3MO0098F Fla
253. f m 11 6 ft Ib 2 Tighten the bolt which install power steering pump bracket Tightening torque 22 N m 2 2 kgf m 15 9 ft Ib PS 58 3 Interconnect the pipes and suction hose Tightening torque Joint nut 39 2 N m 4 kgf m 28 9 CAUTION If a hose is twisted at this step the hose may come into contact with some other parts 1 Suction hose 2 PipeC 4 Connect the connector to the power steering pressure switch 5 Install the pulley belt to the oil pump 6 Check the pulley belt tension lt Ref to ME DOHC TURBO 45 INSPECTION V belt gt 7 Tighten the bolt belt tension Tightening torque 8 0 8 kgf m 5 8 ft lb 8 Install the pulley belt cover 9 Connect the ground terminal of battery 10 Feed the specified power steering fluid lt Ref to PS 72 Power Steering Fluid gt CAUTION Never start the engine before feeding the fluid otherwise vane pump might be seized up POWER ASSISTED SYSTEM POWER STEERING C DISASSEMBLY 1 NON TURBO MODEL 1 Remove the nut and detach oil pump pulley 2 Remove the stay from the oil pump 3 Remove the four bolts which secure rear cover 1 Rear cover 4 Using a screwdriver pry the retaining ring off 1 Retaining ring 2 Screwdriver 5 Extract the shaft from the front casing PS 59 OIL PUMP POWER ASSISTED SYSTEM POWER STEERING 6 Remove the following parts from the front
254. fler 2 Remove the heat shield cover If equipped 3 While holding propeller shaft near center bearing with your hand move it up and down and left and right to check for any abnormal bearing free play DS 16 FRONT AXLE 3 Front Axle A REMOVAL 1 Disconnect the ground cable from battery 2 Jack up the vehicle support it with safety stands and remove the front wheels 3 Unlock the axle nut 4 Remove the axle nut using a socket wrench CAUTION Be sure to loose and retighten axle nut after re moving wheel from vehicle Failure to follow this rule may damage wheel bearings 5 Remove the stabilizer link 6 Remove the disc brake caliper from the housing and suspend it from strut using a wire DRIVE SHAFT SYSTEM 7 Remove the front drive shaft assembly from the hub If it is hard to remove use STs ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXLE SHAFT PULLER PLATE CAUTION Be careful not to damage oil seal lip when re moving front drive shaft e When replacing front drive shaft also replace inner oil seal 8 Remove the disc rotor from the hub If disc rotor seizes up within hub drive disc rotor out by installing an 8 mm bolt in screw hole on the ro tor 9 Remove the cotter pin and castle nut which se cure tie rod end to housing knuckle arm rf B4M2214A A Cotter pin B Castle nut C Tie rod DS 17 FRONT AXLE DRIVE SHAFT SYSTEM
255. fluid must be used e Cover the bleeder with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid e Be careful not to allow dirt or dust to get into the reservoir tank NOTE e During bleeding operation keep the brake reser voir tank filled with brake fluid to eliminate entry of air Brake pedal operating must be very slow For convenience and safety two people should do the work The amount of brake fluid required is approxi mately 500 m 2 16 9 US fl oz 17 6 Imp fl oz for to tal brake system 1 Either jack up the vehicle and place a safety stand under it or lift up the vehicle 2 Remove both front and rear wheels 3 Draw out the brake fluid from master cylinder with syringe 4 Refill the reservoir tank with recommended brake fluid Recommended brake fluid FMVSS 116 fresh or 4 brake fluid 5 Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid Air bleeder screw ji d CAUTION Brake fluid replacement sequence A Front right B Rear left C Front left D Rear right S4M0475A 1 Master cylinder 2 Hydraulic unit 3 Proportioning valve 6 Instruct your co worker to depress the brake pedal slowly
256. force generating mechanism of the strut since air prevents proper dampening force from being produced 2 Checking for the presence of air 1 Place the strut vertically with the piston rod facing up 2 Move the piston rod to the center of its entire stroke 3 While holding the piston rod end with finger tips move the rod up and down 4 If the piston rod moves at least 10 mm 0 39 in in the former step purge air from the strut 3 Air purging procedure 1 Place the strut vertically with the piston rod facing up 2 Fully extend the piston rod 3 With the piston rod fully extended place the piston rod side down The strut must stand ver tically 4 Fully contract the piston rod 5 Repeat 3 or 4 times from the first step NOTE After completely purging air from the strut be sure to place the strut with the piston rod facing up If it is laid down check for entry of air in the strut as outlined under Checking for the presence of air 4 Using a coil spring compressor compress the coil spring NOTE Make sure that the vertical installing direction of coil spring is as shown in the figure 4 0568 1 Flat top side 2 Identification paint 3 Inclined bottom side 5 Set the coil spring correctly so that its end face fits well into the spring seat as shown S4M0353A 6 Install the helper and dust cover to the piston rod 7 Pull the piston rod fully upward and install the
257. front shoe hold down spring and pin with pliers 11 Remove the strut and strut spring 12 Remove the rear shoe hold down spring and pin with pliers 13 Remove the adjuster assembly and adjusting spring from parking brake assembly 14 Remove the parking cable from parking lever 15 Remove the brake shoe B4M1774B 1 Parking brake cable 2 Parking brake lever 16 Using a standard screwdriver raise the retain er Remove the parking lever and washer from brake shoe PB 10 PARKING BRAKE ASSEMBLY REAR DISC BRAKE B INSTALLATION CAUTION Be sure the lining surface is free from oil con tamination Brake grease Dow Corning Molykote No 7439 Part No 725191460 1 Apply brake grease to the following places e Six contact surfaces of shoe rim and back plate packing Contact surface of shoe wave and anchor e Contact surface of lever and strut Contact surface of shoe wave and adjuster as sembly Contact surface of shoe wave and strut Contact surface of lever and shoe wave 2 Install in the reverse order of removal CAUTION e Use new retainers and clinch them when in Stalling the brake shoes to levers Ensure that the parking lever moves smooth ly Do not confuse the left parking lever with right one Do not confuse the left strut with right one NOTE Ensure that the adjuster assembly is securely in stalled with the screw in the left side facing vehicl
258. g Side bearing retainer shim Side bearing retainer 217 Gg 18 B3M0130C 25 Air breather cap 26 Stud bolt 27 Oil filler plug 28 Oil drain plug 5 Bearing preload adjusting washer 17 Side oil seal 29 Rear cover 6 Differential carrier 18 Side gear thrust washer 30 Differential case 7 Front bearing 19 Side gear Tightening torque N m kgf m ft Ib 8 Spacer 20 Pinion mate gear 1 10 3 1 05 7 6 9 Pilot bearing 21 Pinion mate gear washer T2 29 4 3 00 21 7 10 Front oil seal 22 Pinion shaft lock pin T3 49 0 5 0 36 2 11 Companion flange 23 Circlip T4 103 0 10 50 75 9 12 Self locking nut 24 Pinion mate shaft T5 181 4 18 50 133 8 01 4 GENERAL DESCRIPTION DIFFERENTIALS 2 REAR DIFFERENTIAL WITH LSD Y 3 4 5 22 15 17 e 16 12 47 1662 1 Pinion crown gear set 12 Self locking nut 23 Oil filler plug 2 Pinion height adjusting shim 13 Side bearing 24 Oil drain plug 3 Rear bearing 14 O ring 4 Bearing preload adjusting spacer 15 Side bearing retainer shim Tightening torque N m kgf m ft lb 5 Bearing preload adjusting washer 16 Side bearing retainer 1 10 3 1 05 7 6 6 Differential carrier 17 Side oil seal 2 29 4 3 00 21 7 7 Front bearing 18 Gasket T3 49 0 5 00 36 2 8 Collar 19 Differential case T4 103 0 10 50 75 9 9 Pilot bearing 20 Rear co
259. g brake cable end G4M0241 9 Disconnect the rear stabilizer from rear lateral link 10 Remove the bolts which secure trailing link as sembly to the rear housing CAUTION Discard old self locking nut Relpace witha new one 11 Remove the bolts which secure lateral assem bly to the rear housing CAUTION Discard old self locking nut Relpace with a new one DS 23 REAR AXLE DRIVE SHAFT SYSTEM 12 Disengage the BJ from the housing splines and remove the rear drive shaft assembly If itis hard to remove use STs ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXLE SHAFT PULLER PLATE CAUTION Be careful not to damage the oil seal lip when removing rear drive shaft When rear drive shaft is to be replaced also replace inner oil seal with a new one 13 Remove the rear ABS sensor from the back plate only vehicle equipped with ABS H4M1139B 1 ABS sensor 14 Remove the bolts which secure rear housing to strut and separate the two 2 DRUM BRAKE 1 Disconnect the ground cable from battery 2 Jack up the vehicle and remove the rear wheel and wheels CAUTION Be sure to loosen and retighten the axle nut af ter removing wheel from vehicle Failure to fol low this rule may damage wheel bearings 3 Unlock the axle nut 4 Remove the axle nut using a socket wrench 5 Return the parking brake lever and loosen the adjusting nut
260. g cup from side bearing retainer using ST PULLER ASSY ST 398527700 S3M0534A 8 Extract the bearing cone with ST CAUTION Do not attempt to disassemble the parts unless necessary NOTE e Set the puller so that its claws catch the edge of the bearing cone e Never mix up the right and left hand bearing rac es and cones ST 398527700 PULLER SET 9 Remove the crown gear by loosening crown gear bolts CAUTION Further disassembling is not allowed 10 Drive out the pinion shaft lock pin from crown gear side Without LSD NOTE The lock pin is staked at the pin hole end on the dif ferential carrier do not drive it out forcibly before unstaking it ST 899904100 STRAIGHT PINREMOVER 11 Draw out the pinion mate shaft and remove pin ion mate gears side gears and thrust washers Without LSD NOTE The gears as well as thrust washers should be marked or kept separated right and left and front and rear S3M0510A A Side gear B Pinion mate gear C Thrust washer D Differential case E Pinion mate shaft DI 22 REAR DIFFERENTIAL DIFFERENTIALS 12 Hold the companion flange with ST and remove drive pinion nut 498427200 ST FLANGE WRENCH S 53 0511 14 Press the end of drive pinion shaft and extract it together with rear bearing cone preload adjusting spacer and washer NOTE Hold the drive pinion so as not to drop it ST
261. g using snap ring pliers CAUTION Do not reuse removed snap ring Be careful not to scratch pinion and valve as sembly G4M0147 12 Press out the bearing together with the back up washer using pipe of 38 5 to 39 5 1 516 to 1 555 in and press CAUTION Do not reuse removed bearing S4M0403A 1 Bearing 2 Backing washer 3 Oil seal 4 Pipe 13 Remove the oil seal CAUTION Do not reuse removed oil seal PS 32 STEERING POWER ASSISTED SYSTEM POWER STEERING ASSEMBLY 1 RACK HOUSING ASSEMBLY CAUTION Use only SUBARU genuine grease for gearbox Specified grease for gearbox VALIANT GREASE 2 Part No 003608001 1 Clean all parts and tools before reassembling 2 Force fit oil seal using ST ST 34099FA110 INSTALLER CAUTION Be careful not to damage or scratch cylinder in ner wall NOTE Apply specified power steering fluid to oil seal Pay special attention not to install oil seal in wrong direction Push oil seal until the stepped portion of A con tacts end face of B S4M0164B 1 Press 2 seal 3 Apply grease to the teeth of rack so that the grease applied is about as high as teeth and also apply a thin film of grease to the sliding portion of rack shaft CAUTION e When moving rack to stroke end without tie rod attached prevent shocks from being ap plied at the end Do not apply grease to threaded
262. ground Connector amp terminal B264 No 2 Chassis ground CHECK INPUT VOLTAGE OF ABS RELAY Measure the voltage between ABS relay con nector and chassis ground Connector amp terminal B264 No 1 Chassis ground CHECK GROUND CIRCUIT OF ABS RELAY s the resistance less than 5 1 Turn the ignition switch to OFF 2 Measure the resistance between ABS relay connector and chassis ground Connector amp terminal B264 No 3 Chassis ground CHECK ABS RELAY 1 Connect the battery to ABS relay terminal No 1 and 3 2 Measure the resistance between ABS relay terminals CHECK INPUT VOLTAGE ABSCM amp H U s the voltage between 10 and Go to step 10 Repair harness Repair harness connector between battery ignition switch and ABS relay Repair open circuit between ABS relay and chassis ground s the voltage more than 10 V 30 to step 7 ao to step 8 Replace the ABS relay s the resistance less than 10 Go to step 9 2 1 Disconnect the connector from ABSCM amp 7 V connector between battery 2 Run the engine at idle ignition switch and 3 Measure the voltage between ABSCM amp H U ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 1 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U 5 the resistance less than 0 5 Goto step 11 Repair the 1 Tu
263. h unit Go to step 4 Go to step 4 BASIC DIAGNOSTIC PROCEDURE PERFORM THE DIAGNOSIS 1 inspect using Diagnostics Chart with Sub aru Select Monitor Ref to ABS 96 Diagnos tics Chart with Subaru Select Monitor NOTE For diagnostic trouble code DTC list refer to List of Diagnostics Trouble Code DTC Ref to ABS 24 WITHOUT SUBARU SELECT MONITOR LIST List of Diagnostics Trouble Code DTC gt 2 Repair the trouble cause 3 Perform the clear memory mode Ref to ABS 19 CLEAR MEMORY MODE OPERA TION Subaru Select Monitor 4 Perform the inspection mode Ref to ABS 21 Inspection Mode 5 Calling up the diagnostic trouble code DTC Ref to ABS 18 READ DIAGNOSTIC TROU BLE CODE DTC OPERATION Subaru Select Monitor Is no diagnostic trouble code DTC designated and does ABS warning light go out after turning on ABS 5 Complete the diagnosis ABS DIAGNOSTICS Inspect using Diagnostics Chart with Subaru Select Monitor Ref to ABS 96 Diagnos tics Chart with Subaru Select Monitor gt CHECK LIST FOR INTERVIEW ABS DIAGNOSTICS 2 Check List for Interview A CHECK Check the following items about the vehicle s state 1 STATE OF ABS WARNING LIGHT ABS warning light Always comes on 2 Sometimes Ly Only once C Does not come on When how long does it come on Ignition key position R LOCK ACC ON before starting engine
264. haft e When rear drive shaft is to be replaced also replace inner oil seal with a new one DS 25 REAR AXLE DRIVE SHAFT SYSTEM 14 Remove the rear ABS sensor from the back plate only vehicle equipped with ABS H4M1139B 1 ABS sensor 15 Remove the bolts which secure rear housing to strut and separate the two B INSTALLATION 1 DISC BRAKE 1 Connect the rear housing assembly and strut as sembly CAUTION Use a new self locking nut Tightening torque 196 N m 20 kgf m 145 ft Ib 2 Fit the BJ bell joint to the rear housing splines CAUTION Be careful not to damage inner oil seal lip 3 Connect the rear housing assembly to the lateral link assembly CAUTION Use a new self locking nut Tightening torque 137 14 kgf m 101 ft Ib 4 Connect the rear housing assembly to the trail ing link assembly CAUTION Use a new self locking nut Tightening torque 113 N m 11 5 kgf m 83 ft Ib 5 Connect the rear stabilizer to the rear lateral link CAUTION Use a new self locking nut Tightening torque 44 N m 4 5 kgf m 32 5 ft Ib DS 26 DRIVE SHAFT SYSTEM 6 Connect the parking brake cable to the parking brake 7 Install the disc rotor on the rear housing assem bly 8 Install the disc brake caliper on the back plate Tightening torque 52 5 3 kgf m 38 3 ft lb 9 Install the rear ABS sensor and brak
265. hat the air within the boot is appropriate 15 Tighten the band by using ST ST 925091000 BAND TIGHTENING TOOL NOTE Tighten the band until it cannot be moved by hand 16 Tap on the clip with the punch provided at the end of ST ST 925091000 CAUTION Tap to an extent that the boot underneath is not damaged BAND TIGHTENING TOOL 17 Cut off the band with an allowance of about 10 mm 0 39 in left from the clip and bend this allow ance over the clip CAUTION Be careful so that the end of the band is in close contact with clip 18 Fix up the boot on the BJ or EBJ in the same manner NOTE Extend and retract the DOJ to provide equal grease coating E INSPECTION Check the removed parts for damage wear corro sion etc If faulty repair or replace 1 DOJ Double Offset Joint Check seizure corrosion damage wear and ex cessive play 2 Shaft Check excessive bending twisting damage and wear 3 BJ Bell Joint and EBJ Eightball Bell Joint Check seizure corrosion damage and excessive play 4 Boot Check for wear warping breakage or scratches 5 Grease Check for discoloration or fluidity DS 43 REAR DRIVE SHAFT BOOTS DRIVE SHAFT SYSTEM 8 Rear Drive Shaft Boots A INSPECTION Inspect the wear warping breakage or scratches for boot If faulty repair or replace REPLACEMENT 1 Disconnect the ground terminal from battery 2 Lift up the vehicle and remove the
266. he boot ring Be careful not to scratch the boot 8 Apply a coat of specified grease to lock pin and guide pin outer surface cylinder inner surface and boot grooves Grease NIGLUBE RX 2 Part No 003606000 SC EMI Jj s KAR B4M1176B 1 Pin boot 2 Lock pin or guide pin 3 Apply grease 9 Install the lock pin boot and guide pin boot on support BR 22 FRONT DISC BRAKE ASSEMBLY BRAKE E INSPECTION NOTE Repair or replace the faulty parts 1 Check the caliper body and piston for uneven wear damage or rust 2 Check the rubber parts for damage or deteriora tion BR 23 f REAR BRAKE PAD BRAKE 5 Rear Brake Pad A REMOVAL 1 Set the vehicle on the lift 2 Loosen the wheel nuts 3 Jack up the vehicle and remove the rear wheel 4 Remove the lock pin 5 Raise the caliper body 6 Remove the pad from support NOTE If the brake pad is difficult to remove use the same procedure as for front disc brake pad Ref to BR 16 REMOVAL Front Brake Pad Rz B INSTALLATION 1 Apply a thin coat of Molykote AS880N Part No 26298AC000 to the frictional portion between pad and pad clip 2 Install the pad on support 3 Install the caliper body on support Tightening torque 37 N m 3 8 kgf m 27 5 ft Ib NOTE If it is difficult to push the piston during pad replace ment loosen the air bleeder to facilitate work C INSPE
267. he jack up plate from lower part of crossmember 3 Remove the sub frame lt Ref to FS 16 RE MOVAL Sub Frame gt 4 Remove the bolt and nut which secure the stabi lizer to crossmember 5 Remove the bolts which secure the stabilizer link to front transverse link B INSTALLATION 1 Install in the reverse order of removal NOTE Install the bushing on front crossmember side while aligning it with paint mark on stabilizer Ensure the bushing and stabilizer have the same identification colors when installing 1 Mark stamped on stabilizer 2 Bushing identification color 2 Always tighten the rubber bushing location when wheels are in full contact with the ground and ve hicle is curb weight Tightening torque Sedan turbo model Jack up plate to crossmember 20 N m 2 0 kgf m 14 5 ft lb Stabilizer link to front transverse link 45 4 6 kgf m 33 ft lb Stabilizer to crossmember 25 N m 2 5 kgf m 18 1 ft lb Tightening torque Except sedan turbo model Jack up plate to crossmember 20 N m 2 0 kgf m 14 5 ft lb Stabilizer link to front transverse link 30 N m 3 1 kgf m 22 ft lb Stabilizer to crossmember 25 N m 2 5 kgf m 18 1 ft Ib 3 Install the sub frame Ref to FS 16 INSTALLA TION Sub Frame C INSPECTION 1 Check the bushing for cracks fatigue or dam age 2 Check the stabilizer link for deformities cracks or damage and bushing for protrusions from the h
268. he lock nut While holding adjusting screw with a wrench tighten the lock nut using ST ST 926230000 SPANNER Tightening torque Lock nut 39 4 0 kgf m 29 ft lb NOTE e Hold the adjusting screw with a wrench to pre vent it from turning while tightening lock nut Make adjustment so that the steering wheel can be rotated fully from lock to lock without binding 21 Check for service limit as per article of Service limit Ref to PS 42 INSPECTION Steering Gearbox gt Make replacement and adjustment if necessary 22 Take off the gearbox from ST 23 Install the four pipes on the gearbox 1 Connect the pipe A and B to the gearbox Tightening torque 13 1 3 kgf m 9 4 ft lb 2 Connect the pipe E and F to the gearbox Tightening torque Pipe E 15 1 5 kgf m 10 8 ft Ib Pipe F 25 N m 2 5 kgf m 18 1 ft Ib PS 41 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING E INSPECTION 1 BASIC INSPECTION 1 Clean all disassembled parts and check for wear damage or any other faults then repair or replace as necessary 2 When disassembling check inside of gearbox for water If any water is found carefully check boot for damage input shaft dust seal adjusting screw and boot clips for poor sealing If faulty replace with new parts 1 1 Bend of input shaft If the bend or damage is excessive replace the entire 2 Damage on serration gearbox 1 Crack or damage If the outer wal
269. he pipe C from the oil pump 4 Disconnect the pipe D from the return hose CAUTION Do not allow fluid from the hose end to come into contact with pulley belt To prevent foreign matter from entering the hose and pipe cover the open ends of them with a clean cloth 1 Bolt A 2 PipeC 3 Pipe D 7 TURBO model 1 Remove the air intake duct air cleaner up per cover and air intake boot Ref to IN DOHC TURBO 8 REMOVAL Air Intake Duct and Ref to IN DOHC TURBO 7 REMOVAL Air Cleaner 2 Remove the two bolts fixing pipe C and D 3 Remove the coolant filler tank WA RA ESSENT 4 Disconnect the pipe C from oil pump 5 Disconnect the pipe D from the return hose CAUTION Do not allow fluid from the hose end to come into contact with pulley belt To prevent foreign matter from entering the hose and pipe cover the open ends of them with a clean cloth 1 Pipe C 2 Pipe D PS 48 PIPE ASSEMBLY POWER ASSISTED SYSTEM POWER STEERING INSTALLATION 2 Install the coolant filler tank Turbo model 1 Temporarily tighten the bolts fixing pipe C and D Tightening torque CAUTION T1 19 N m 1 9 kgf m 13 7 Visually check that hose between tank and pipe T2 21 N m 2 1 kgf m 15 2 ft lb D is free from bending or twisting e Non TURBO model gt 1 2 3 Pipe D TURBO model 1
270. heck the fol lowing working sequence 1 The FL wheel performs decompression holding and compression in sequence and subsequently the FR wheel repeats the cycle 2 The RR wheel performs decompression holding and compression in sequence and subsequently the RL wheel repeats the 7 Read the values indicated on the brake tester and check if the fluctuation of values when decom pressed and compressed meet the standard val ues Front wines Initial value 981 N 981 N 100 kgf 221 Ib 100 kgf 221 Ib When 490 N 490 N 50 kgf 110 10 50 kgf 110 Ib decompressed or less or less When 981 N 981 N compressed 100 kgf 221 Ib 100 kgf 221 Ib E or more or more 8 After checking also check if any irregular brake pedal tightness is felt ABS 10 ABS SEQUENCE CONTROL ABS 3 ABS Sequence Control A OPERATION 1 Under the ABS sequence control after the hy draulic unit solenoid valve is driven the operation of the hydraulic unit can be checked by means of the brake tester or pressure gauge 2 ABS sequence control can be started by diagno sis connector or select monitor 1 ABS SEQUENCE CONTROL WITH DIAG NOSIS CONNECTOR 1 Connect the diagnosis terminals to terminals No 3 and No 6 of the diagnosis connector beside driv er s seat heater unit 1 Diagnosis connector 2 Diagnosis terminals 3 3 terminal 4 6 terminal 2 Set the speed of all wheels at 4 km h 2
271. heel moval 3 Disconnect the front ABS sensor connector lo Do not pull the sensor harness during remov cated next to the front strut mounting house in en al gine compartment 4 Remove the bolts which secure sensor harness to strut to body B4M1728C 1 To front ABS sensor connector 2 Bracket ABS 14 FRONT ABS SENSOR ABS B INSTALLATION 1 Temporarily install the front ABS sensor on housing CAUTION Be careful not to strike the ABS sensor s pole piece and tone wheel s teeth against adjacent metal parts during installation 2 Install the front ABS sensor on strut and wheel apron bracket Tightening torque 32 3 3 kgf m 24 ft lb 1 To front ABS sensor connector 2 Bracket 3 Place a thickness gauge between the ABS sen sor s and tone wheel s tooth face After standard clearance is obtained over the entire perimeter tighten the ABS sensor on housing to specified torque ABS sensor standard clearance 0 3 0 8 mm 0 012 0 031 in Tightening torque 32 3 3 kgf m 24 ft lb CAUTION Check the marks on the harness to make sure that no distortion exists RH White LH Yellow NOTE the clearance is outside specifications readjust 4 After confirmation of the ABS sensor clearance connect the connector to ABS sensor 5 Install the wheel 6 Connect the battery ground terminal to battery ABS 15 FRONT ABS SENSOR ABS C I
272. heir appearance and safety do the following 1 Do not damage the aluminum wheels during re moval disassembly installation wheel balancing etc After removing the aluminum wheels Place them on a rubber mat etc 2 While the vehicle is being driven be careful not to ride over sharp obstacles or allow aluminum wheels to contact the shoulder of the road 3 When installing a tire chain be sure to install it properly not to have a slack otherwise it may hit the wheel while driving 4 When washing the aluminum wheel use neutral synthetic detergent and water Avoid using the cleanser including abrasive hard brushes or an automatic car washer WT 6 WHEEL BALANCING WHEEL AND TIRE SYSTEM 5 Wheel Balancing A REPLACEMENT 1 Remove the balance weights 2 Using the dynamic balancing measure wheel balance 3 Select a weight close to the value measured by dynamic balancing Balance weight part number For steel wheel Weight 723141290 5 g 0 18 oz 0760 Balance wei rt number 6899409 4 Install the selected weight to the point designat ed by dynamic balancing 5 Using the dynamic balancing measure wheel balance again Check that wheel balance is cor rectly adjusted B INSPECTION 1 Proper wheel balance may be lost if the tire is re paired or if it wears Check the tire for dynamic bal ance and repair as necessary 2 To check for dynamic balance
273. hese exceeds the service limit replace the If it exceeds the service limit replace the pulley with a new one replace the oil pump with a new one E INSPECTION 1 Damage on body surfaces 2 Excessive wear on hole into which spool valve is inserted 1 Front casing 3 Wear and damage on cartridge assembly Replace win amp valve as selective fit is made mounting surface 4 Wear and damage on surfaces in contact with shaft and oil seal bushing and oil seal Ridge wear on sliding surfaces If the damage is serious replace with a new car 9 Spring Replace with a new one oil pump with a new one new one Oil pump emits a noise that is markedly different rack or deterioration Replace it with a new one 1 BASIC INSPECTION 1 Damage on body surfaces 2 Wear and damage on sliding surfaces 3 Wear and damage on rotor mounting surfaces Excessive wear on nose radius and side sur 6 Vane faces tridge assembly 10 Bolts and nuts Damage on threads Replace with a new one 1 Crack damage or oil leakage Replace the oil pump with a new one Replace it with a new one Check the resistance to the rotation of pulley tone and loudness from a sound of a new oil pump Bracket Replace it with new PS 66 2 SERVICE LIMIT Make a measurement as follows If it exceeds the specified service limit replace the parts with new ones CAUTION Fix oil pump o
274. hin approx 12 seconds connecting and disconnecting terminal 6 and diagnosis termi nal for at least 0 2 seconds each time Diagnostic trouble code DTC indicatione mode Memory erase mode GND Low level GND open High level Terminal 8 0 2 sec 0 2 sec or more or more 12 sec or less NOTE After diagnostics is completed make sure to clear memory Make sure only start code 11 is shown after memory is cleared 2 WITH SUBARU SELECT MONITOR Refer to SUBARU SELECT MONITOR for information about how to clear the diagnostic trouble code DTC Ref to ABS 18 Subaru Select Monitor ABS 22 ABS WARNING LIGHT ILLUMINATION PATTERN ABS DIAGNOSTICS 10 ABS Warning Light Illumination Pattern A INSPECTION ignition key switch Iluminates Goes Out Goes out ABS warning light 4 0781 1 When the ABS warning light does not illuminate accordance with this illumination pattern there must be an electrical malfunction 2 When the ABS warning light remains constantly OFF repair the ABS warning light circuit or diagnosis cir cuit lt Ref to ABS 29 Diagnostics Chart with Diagnosis Connector gt NOTE Even though the ABS warning light does not go out 1 5 seconds after it illuminates the ABS system operates normally when the warning light goes out while driving at approximately 12 km h 7 MPH However the Anti lock brakes do not work while the ABS warning light is illuminated
275. iagnostics Chart with Diagnosis Connector Ref to ABS 57 DTC 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR LH Diagnostics Chart with Diagnosis Connector Ref to ABS 61 DTC 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR LH Diagnostics Chart with Diagnosis Connector ABS 24 LIST OF DIAGNOSTICS TROUBLE CODE DTC ABS DIAGNOSTICS Contents of diagnosis lt Ref to ABS 66 DTC 41 ABNORMAL ABS CONTROL MODULE Diagnostics Chart with Diagnosis Connector gt 42 lt Ref to 5 69 DTC 42 SOURCE VOLTAGE IS ABNORMAL 9 Diagnostics Chart with Diagnosis Connector gt 44 or AT conto abnormal lt Ref to ABS 74 DTC 44 A COMBINATION OF AT CONTROL ABNORMAL Diagnostics Chart with Diagnosis Connector 51 to ABS 77 51 ABNORMAL VALVE RELAY Diagnostics y Chart with Diagnosis Connector ea lt Ref to ABS 81 DTC 52 ABNORMAL MOTOR AND OR MOTOR RELAY Diagnostics Chart with Diagnosis Connector gt Diagnostics Chart with Diagnosis Connector gt Ref to ABS 89 DTC 56 ABNORMAL G SENSOR OUTPUT VOLT AGE Diagnostics Chart with Diagnosis Connector gt ABS 25 LIST OF DIAGNOSTICS TROUBLE CODE DTC ABS DIAGNOSTICS 2 WITH SUBARU SELECT MONITOR Communication for ini Select monitor commu lt Ref to ABS 96 COMMUNICA
276. ic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnositc trouble code Go to step 6 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary poor contact ABS 141 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ABS 142 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Y DTC 51 VALVE RELAY MALFUNCTION DIAGNOSIS Faulty valve relay TROUBLE SYMPTOM ABS does not operate ABS 143 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY SBF 3 SBF 1 pi No 8 IGNITION SWITCH ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SOLENOID VALVE FR INLET FR OUTLET RL INLET RL OUTLET HR RR OUTLE PUMP MOTOR IQ BR0087 629128 25 26 ABS 144 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS 4 Step Check Yes No CHECK INPUT VOLTAGE OF RELAY HOLD Is the voltage more than 10 V 3o to step 2 3epair open circuit ER n harness 1 Turn the ignition switch to OFF etween battery 2 Remove the fuse and Relay holder 3 Measure the voltage between ABS relay connector connector and chassis ground Connector amp terminal B225
277. ied points e Apply grease onto sliding or revolution surfaces before installation Before installing O rings or snap rings apply suf ficient amount of grease to avoid damage and de formation Before securing part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice DS 8 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 922431000 AXLE SHAFT e Used for installing axle shaft into housing INSTALLER Used with ADAPTER 927390000 B4M2386 925091000 BANDTIGHTENING Used for tightening boot band Except front TOOL axle housing side A Jig for band 926470000 AXLE SHAFT PULLER 927060000 HUB REMOVER B4M2389 Ratchet wrench Used for removing axle shaft e Used for removing front hub e Used with HUB STAND 927080000 DS 9 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927420000 HUB REMOVER Used for removing rear hub Used with HUB STAND 927080000 927080000 HUB STAND 5 0981 Used for disassembling and assembling hub bolt in hub BEARING PULLER Used for disassembling and assembling front housing bearing Used with HOUSING STAND 927400000 927140000 AXLE SHAFT Same as plate 2 included in AXLE SHAFT PULLER PLATE PULLER 92
278. ignment lt Ref to FS 8 SPECTION Wheel Alignment gt RS 9 REAR STABILIZER REAR SUSPENSION 3 Rear Stabilizer A REMOVAL 1 Jack up the rear part of the vehicle support it with safety stands rigid racks 2 Remove the bolts which secure stabilizer link to rear lateral link 500017 3 Remove the bolt which secures stabilizer sta bilizer bracket 500027 INSTALLATION 1 Install the reverse order of removal NOTE e Install the bushing while aligning it with paint mark on stabilizer e Ensure that the bushing and stabilizer have the same identification colors when installing 1 Mark stamped on stabilizer 2 Bushing identification color 2 Always tighten the rubber bushing location when wheels are in full contact with the ground and vehi cle is curb weight Tightening torque Stabilizer link to rear lateral link 45 N m 4 6 kgf m 33 2 ft lb Stabilizer to stabilizer bracket 25 N m 2 5 kgf m 18 1 ft Ib C INSPECTION 1 Check the bushing for cracks fatigue or dam age 2 Check the stabilizer links for deformities cracks or damage and bushing for protrusions from the hole of stabilizer link RS 10 REAR TRAILING LINK REAR SUSPENSION 4 Rear Trailing Link A REMOVAL 1 Loosen the rear wheel nuts 2 Jack up the vehicle support it with safety stands rigid racks and remove the rear wheels 3 Remove both rear parking brake c
279. inc ino odis aer Re JO rac e i la P nece DT Mer aco Reno Arce 6 cce oi roo Pr epi omnid eio a ee T E ec gee oio C diii cdm ABS 100 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS B NO TROUBLE CODE DIAGNOSIS e ABS warning light circuit is shorted TROUBLE SYMPTOM ABS warning light remains on e NO TROUBLE CODE displayed on the select monitor NOTE When the ABS warning light is OFF and NO TROUBLE CODE is displayed on the select monitor the sys tem is in normal condition ABS 101 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY SBF 3 SBF 1 7 en v I e LJ IGNITION SWITCH a C RELAY HOLDER lt No 13 8108 ENGINE MODEL NON TURBO ENGINE MODEL COMBINATION METER DIAGNOSIS A TERMINAL RELAY HOLDER 0083 5 102 ee m ee me ae Aa e i EE T e RENE ee PX m a DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Yes Go to step 2 Go to step 3 Control Unit ABSCM amp H U gt CHECK WIRING HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connecto
280. ion switch to ON 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 25 Chassis ground CHECK GROUND CIRCUIT OF MOTOR 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 26 Chassis ground CHECK INPUT VOLTAGE OF RELAY HOLD ER 1 Turn the ignition switch to OFF 2 Remove the fuse 3 Measure the voltage between ABS relay connector and chassis ground Go to step 4 Connector amp terminal 225 No 5 Chassis ground 5 CHECK INPUT VOLTAGE OF ABS RELAY 15 the voltage more than 10 V to step 6 Repair open circuit 1 Install the fuse in harness 2 Remove the ABS relay between battery 3 Turn the ignition switch to ON and Relay holder 4 Measure the voltage between ABS relay connector connector and chassis ground Connector amp terminal B264 2 Chassis ground CHECK INPUT VOLTAGE OF ABS RELAY voltage more than 10 V Repair harness Measure the voltage between ABS relay con connector nector and chassis ground between battery Go to step 8 Go to step 9 Connector amp terminal ignition switch and Go to step 10 Repair Ge connector between battery and ABSCM amp H U and check fuse SBF holder Repair the ABSCM amp H U ground harness is the resis
281. ir open circuit 5 the voltage more than 10 V Go to step 2 ER 1 Turn the ignition switch to OFF 2 Remove the fuse 3 Measure the voitage between ABS relay connector and chassis ground Connector amp terminal B225 No 5 Chassis ground 2 CHECK RELAY HOLDER s the fuse blown out Replace the fuse 3 CHECK INPUT VOLTAGE OF ABS RELAY s the voltage more than 10 V Go to step 4 1 Instail the fuse 2 Remove the ABS relay 3 Turn the ignition switch to ON 4 Measure the voltage between ABS relay connector and chassis ground Connector amp terminal B264 2 Chassis ground CHECK INPUT VOLTAGE OF ABS RELAY Measure the voltage between ABS relay con nector and chassis ground Connector amp terminal B264 1 Chassis ground CHECK GROUND CIRCUIT OF ABS RELAY 1 Turn the ignition switch to OFF 2 Measure the resistance between ABS relay connector and chassis ground Connector amp terminal B264 3 Chassis ground CHECK ABS RELAY 1 Connect the battery to ABS relay terminal No 1 and 3 2 Measure the resistance between ABS relay terminals CHECK INPUT VOLTAGE OF ABSCM amp H U 1 Disconnect the connector ABSCM amp H U 2 Run the engine at idle 3 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 1 4 Chassis ground CHECK GROUND CIRCUIT OF ABSCM amp H U 1 Turn
282. isplayed ON or OFF ABS operation signal from ABS control module to TCM ON or OFF NOTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MANUAL 3 CLEAR MEMORY MODE 1 On the Main Menu display screen select the 2 Each System Check and press the YES key 2 On the System Select Menu display screen select Brake System and press the YES key 3 Press the YES key after displayed the information of engine type 4 On the Brake Control Diagnosis display screen select the Clear Memory and press the YES key 5 When the Done and turn ignition switch OFF are shown on the display screen turn the Subaru Select Monitor and ignition switch to OFF NOTE For detailed operation procedure refer to the SUBARU SELECT MONITOR OPERATION MANUAL Valve Relay Signal Motor Relay Signal ABS Signal to TCM ABS Warning Lamp Motor Relay Monitor Valve Relay Monitor CCM Signal ABS 19 READ DIAGNOSTIC TROUBLE CODE DTC ABS DIAGNOSTICS 7 Read Diagnostic Trouble 2 Turn the ignition switch OFF Code DTC c Sever ae oe connector terminal 6 to Hes idi uil iie the diagnostic mode 1 WITHOUT SUBARU SELECT MONITOR m to identify diagnostic trouble code 1 Take out the diagnosis connector from side of driver s seat heater unit 6 After the start code 11 is shown the diagnostic trouble code DTC will be shown in order of the last inform
283. it ABSCM amp H U Go to step 13 Go to step 14 A temporary poor contact NOTE Check harness and connectors between AB SCM amp H U and ABS sensor DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS H DTC 22 ABNORMAL ABS SENSOR FRONT RH NOTE For the diagnostic procedure refer to DTC 28 lt Ref to ABS 47 DTC 28 ABNORMAL ABS SENSOR REAR LH Diagnostics Chart with Diagnosis Connector gt I DTC 24 ABNORMAL ABS SENSOR FRONT LH NOTE For the diagnostic procedure refer to DTC 28 lt Ref to ABS 47 DTC 28 ABNORMAL ABS SENSOR REAR LH Diagnostics Chart with Diagnosis Connector gt J DTC 26 ABNORMAL ABS SENSOR REAR RH NOTE For the diagnostic procedure refer to DTC 28 lt Ref to ABS 47 DTC 28 ABNORMAL ABS SENSOR REAR LH Diagnostics Chart with Diagnosis Connector gt ABS 46 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS K DTC 28 ABNORMAL ABS SENSOR REAR LH DIAGNOSIS e Faulty ABS sensor signal noise irregular signal etc e Faulty harness connector TROUBLE SYMPTOM ABS does not operate ABS 47 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT jee l 1 I i SHIELD JOINT CONNECTOR 1 i 1 t 1 1 1 t i i F 1
284. ithin 15 seconds after stopping the engine brake booster is functioning properly If defective refer to AIR TIGHTNESS CHECK Ref to BR 40 INSPECTION Brake Booster Lack of boosting action check Turn off the engine and set the vacuum gauge reading at 0 Then check the fluid pressure when brake pedal is depressed The pressure must be greater than the standard value listed Brake pedal 294 N force 15 kgf 33 Ib 30 kgf 66 Ib 6 kg cm 85 psi 15 kg cm 213 psi BR 41 BRAKE BOOSTER BRAKE Boosting action check Set the vacuum gauge reading at 66 7 kPa 500 mmHg 19 69 inHg by running engine Then check the fluid pressure when brake pedal is de pressed The pressure must be greater than the standard value listed force 15 kgf 33 Ib 30 kgf 66 Ib 58 kg cm 825 psi 5 296 kPa e 9 120 93 kg cm 1 323 psi sure BR 42 PROPORTIONING VALVE BRAKE 13 Proportioning Valve A REMOVAL 1 Remove the brake pipe from proportioning valve at four places 2 Remove the proportioning valve from its bracket CAUTION Do not disassemble or adjust the proportioning valve The proportioning valve must be re placed as an assembly B INSTALLATION 1 Install the proportioning valve to bracket 2 Connect the brake pipes correctly to proportion ing valve 3 Bleed air then check each joint of brake pi
285. l 4 Brake spring 5 Remove the brake pedal pad 2 Unbolt and then remove the brake pedal 1 2 3 4 Plug Stopper Brake pedal Brake pedal spring 4 Remove the brake pedal pad BR 52 BRAKE PEDAL BRAKE D ASSEMBLY 1 Attach the stop light switch etc to pedal bracket temporarily 2 Clean the inside of bores of clutch pedal and brake pedal apply grease and set bushings into bores 3 Align bores of pedal bracket clutch pedal and brake pedal attach brake pedal return spring and clutch pedal effort reducing spring vehicle with hill holder and then install the pedal boit NOTE Clean up inside of bushings and apply grease be fore installing the spacer Tightening torque 29 N m 3 0 kgf m 21 7 ft lb B4M1753C 4 Set the brake pedal position by adjusting the po sition of stop light switch Pedal position L 125 9 mm 4 96 in Tightening torque T 8 N m 0 8 kgf m 5 8 ft lb B4M1754B E INSPECTION 1 Move the brake and clutch pedal pads in the lat eral direction with a force of approximately 10 N 1 kgf 2 16 to ensure pedal deflection is in specified range CAUTION If excessive deflection is noted replace the bushings with new ones Deflection of brake and clutch pedal Service limit 5 0 mm 0 197 in or less 54 0135 1 Clutch pedal 2 Brake pedal BR 53 BRAKE PEDAL BRAKE 2 Check the position
286. l slips the lip is worn out or damage is 2 us 2 Wear found replace it with new one 1 Adjust the backlash properly By measuring turning torque of gearbox and sliding resis tance of rack check if rack and pinion engage uniformly and smoothly with each other Refer to Service limit 2 Keeping rack pulled out ail the way so that all teeth emerge check teeth for damage Even if abnormality is found in either 1 or 2 replace the entire gearbox Poor mating of rack with pinion 1 Bend of rack shaft 2 Bend of cylinder portion 3 Crack or damage on cast iron portion Replace the gearbox with new one Rack and pinion If the free play of rack shaft in radial direction is out of the specified range replace the gearbox with new one Refer to Service limit If the free plays of input shaft in radial and axial directions are out of the specified ranges replace the gearbox with new one Refer to Service limit Crack damage or deterioration 1 Looseness of ball joint seal spring Boot clip 10 1 Damage to flared surface Replace 4 Wear or damage on rack bush 5 Wear on input shaft bearing UJ 2 Damage to flare nut 3 Damage to pipe PS 42 2 SERVICE LIMIT Make a measurement as follows If it exceeds the specified service limit adjust or replace NOTE STEERING GEARBOX POWER ASSISTED SYSTEM
287. lamp and ABS sensor harness Models equipped with ABS 4 Remove the bolt which secures trailing link to trailing link bracket Qd Mm muU p By 1 Trailing link 5 Remove the bolt which secures trailing link to rear housing B INSTALLATION Install in the reverse order of removal CAUTION Always tighten the rubber bushing location when wheels are in full contact with the ground and vehicle is at curb weight condition NOTE Check the wheel alignment and adjust if necessary RS 11 REAR TRAILING LINK REAR SUSPENSION C DISASSEMBLY 2 REAR BUSHING 1 Remove the housing lt Ref to DS 23 REMOV 1 FRONT BUSHING AL Rear Axle gt Using ST press the front bushing out of place 2 Using ST press the rear bushing out of place ST 927720000 INSTALLER amp REMOVER ST 927730000 INSTALLER amp REMOVER SET SET S4M0358A S4M0359A 1 Press 1 Press 2 Trailing link 2 Housing RS 12 REAR TRAILING LINK REAR SUSPENSION D ASSEMBLY 2 REAR BUSHING 1 FRONT BUSHING 1 Using ST press the bushing into trailing link ST 927730000 INSTALLER amp REMOVER Using ST press the bushing into trailing link SET ST 927720000 INSTALLER amp REMOVER SET PE or If it is difficult to press the bushing into trailing link CAUTION apply water diluted TIRE LUBE to the inner surface When installing the bushing turn ST plunger of ST as a lubricant upside down
288. le adjusting nut and con sole bracket 6 Remove the parking brake lever 1 Parking brake lever 2 Cable B INSTALLATION Install in the reverse order of removal Tightening torque Parking brake lever 18 1 8 kgf m 13 0 ft lb Adjusting nut 6 0 6 kgf m 4 4 ft Ib Be sure to pass the cable through the guide in side tunnel Be sure to adjust the lever stroke lt Ref to PB 7 ADJUSTMENT Parking Brake Lever gt S4M0473A 1 Equalizer 2 Inner cable end PB 6 PARKING BRAKE LEVER PARKING BRAKE C INSPECTION While pulling the parking brake lever upward count the notches Lever stroke 7 to 8 notches when pulled with a force of 196 20 kof 44 Ib If incorrect adjust the parking brake lt Ref to PB 12 ADJUSTMENT Parking Brake As sembly Rear Disc Brake gt D ADJUSTMENT 1 Remove the console box lt Ref to El 41 RE MOVAL Console Box gt 2 Forcibly pull the parking brake lever 3 to 5 times 3 Adjust the parking brake lever by turning adjust er until the parking brake lever stroke is set at 7 to 8 notches with an operating force of 196 N 20 kof 44 Ib 4 Tighten the lock nut Lever stroke 7 to 8 notches when pulled with a force of 196 N 20 kof 44 Ib Tightening torque Lock nut 5 9 0 6 kgf m 4 3 ft lb 1 Parking brake lever 2 Lock nut 3 Adjusting nut 5 Install the console box lt Ref to El 41 INS
289. lignment gauge 2 Turning radius gauge NOTE Refer to the SPECIFICATIONS for the camber values Front lt Ref to FS 2 SPECIFICATIONS General Description gt Rear lt Ref to RS 2 SPECIFICATIONS General Description gt Front camber adjustment 1 Loosen the two self locking nuts located at the lower front portion of strut CAUTION When the adjusting bolt needs to be loos ened or tightened hold its head with a wrench and turn the self locking nut Discard the loosened self locking nut and re place with a new one 2 Turn the camber adjusting bolt so that the cam ber is set at the specification NOTE Moving the adjusting bolt by one scale graduation changes the camber by approximately 0 10 i 54 0300 1 Strut 2 Adjusting bolt 3 Housing 4 Outer 5 Inner 6 Camber is increased 7 Camber is decreased FS 10 WHEEL ALIGNMENT Left side FRONT SUSPENSION Right side Rotate counterclock Camber is increased a wise Camber is decreased B4M0350 3 Tighten the two self locking nuts Tightening torque 175 17 8 kgf m 129 ft lb 3 CASTER Inspection 1 Place the front wheel on turning radius gauge Make sure the ground contacting surfaces of front and rear wheels are set at the same height 2 Set the ST into the center of the wheel and then install the wheel alignment gauge ADAPTER ST 9
290. linder surrounding then wipe up the wa ter 8 Bleed air from the brake line Ref to 46 BRAKE LINE PROCEDURE Air Bleeding 2 BRAKE LINE NOTE e During the bleeding operation keep the brake reservoir tank filled with brake fluid to eliminate en try of air e Brake pedal operating must be very slow e For convenience and safety two people should do the work 1 Make sure that there is no leak from joints and connections of the brake system 2 Fit one end of vinyl tube into the air bleeder and put the other end into a brake fluid container BR 46 AIR BLEEDING BRAKE CAUTION Brake fluid replacement sequence A Front right B Rear left C Front left D Rear right S4M0475A 1 Master cylinder 2 Hydraulic unit 3 Proportioning valve 3 Slowly depress the brake pedal and keep it de pressed Then open the air bleeder to discharge air together with the fluid Release the air bleeder for 1 to 2 seconds Next with the bleeder closed slowly release the brake pedal Repeat these steps until there is no more air bub bles in the vinyl tube Allow 3 to 4 seconds between two brake pedal op erations CAUTION Cover the bleeder with waste cloth when loos ening it to prevent brake fluid from being splashed over surrounding parts NOTE Brake pedal operating must be very slow 4 Tighten the air bleeder securely when no air bub bles are visible Air bleede
291. ls at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the pad wears down to such an ex tent that the end of the wear indicator contacts the disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard re place the pad e When replacing the pads replace the pads of the right and left wheels at the same time 2 Apply a thin coat of Molykote AS880N Part No 26298 000 to the frictional portion between pad and pad clip 3 Apply a thin coat of Molykote AS880N Part No 26298AC000 to the frictional portion between pad and inner shim 2 2 4 Install the pads on support 5 Install the caliper body on support Tightening torque Non turbo model 26 5 N m 2 70 kgf m 19 5 ft lb Turbo model 37 N m 3 8 kgf m 27 5 ft Ib 6 Connect the brake hose Tightening torque 18 N m 1 8 kgf m 13 0 ft Ib CAUTION Replace the brake hose gaskets with new ones 7 Bleed air from the brake system lt Ref to BR 46 Air Bleeding gt BR 19 FRONT DISC BRAKE ASSEMBLY BRAKE C DISASSEMBLY 1 NON TURBO MODEL 1 Clean mud and foreign particles from the caliper body assembly and support CAUTION Be careful not to allow foreign particles to enter inlet at brake hose connector 2 Gradually supply compressed air via caliper body brake hose to force piston out CAUTION Place a wo
292. luid must be used Cover the bleeder with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid Be careful not to allow dirt or dust to get into the reservoir tank NOTE e Start with the brakes wheels connected to the secondary chamber of the master cylinder The time interval between two brake pedal oper ations from the time when the pedal is released to the time when it is depressed another time shall be approximately 3 seconds e The air bleeder on each brake shall be released for 1 to 2 seconds 1 MASTER CYLINDER NOTE e f the master cylinder is disassembled or reser voir tank is empty bleed the master cylinder e During the bleeding operation keep the brake reservoir tank filled with brake fluid to eliminate en try of air Brake pedal operating must be very slow e For convenience and safety two people should do the work 1 Disconnect the brake line at primary and sec ondary sides 2 Cover the master cylinder with vinyl bag 3 Carefully depress and hold the brake pedal 5 Repeat the above step3 and 4 until brake fluid is completey bled from outlet plug 6 Remove the vinyl bag then connect the brake pipe to master cylinder Tightening torque 8 0 8 kgf m 5 8 ft Ib 7 Using water wash off the spilt brake fluid at the master cy
293. move the outer and inner oil seals CAUTION Do not use old oil seals 5 Using flat bladed screwdriver remove the snap ring CAUTION Be careful not to damage housing at removal 6 Using ST1 support housing securely 7 Using ST2 press inner race to drive out outer bearing ST1 927400000 HOUSING STAND ST2 927100000 BEARING PULLER CAUTION Do not remove outer race unless it is faulty e Discard outer race after removal Do not replace inner or outer race separately always replace as a unit DS 20 FRONT AXLE DRIVE SHAFT SYSTEM D ASSEMBLY 1 Attach the hub to ST securely HUB STAND ST 927080000 2 Using a hydraulic press press the new hub bolts into place CAUTION Be sure to press hub bolts until their seating surfaces contact the hub NOTE Use 12 mm 0 47 in dia holes in HUB STAND to prevent bolts from tilting 3 Clean the dust or foreign particles from inside the housing 4 Using ST1 and ST2 press a new bearing into place ST1 927400000 HOUSING STAND ST2 927100000 BEARING PULLER CAUTION Always press outer race when installing bear ing Becareful not to remove the plastic lock from inner race when nstalling bearing Charge bearing with new grease when outer race is not removed Do not apply pressure more than 30 kN 3 1 ton 2 8 US ton 3 1 Imp ton Specified grease SHELL 6459N 5 Using pliers install the snap
294. mpletely 3 Temporarily tighten the bolt on the gearbox side Raise the universal joint to make sure the bolt is properly passing through the cutout at the serrated section 4 Tighten the bolt Tightening torque 24 N m 2 4 kgf m 17 4 ft Ib CAUTION Make sure that universal joint bolt is tight ened through notch in shaft serration Excessively large tightening torque of uni versal joint bolts may lead to heavy steering wheel operation Standard clearance between gearbox to DOJ Over 14 mm 0 55 in PS 20 UNIVERSAL JOINT POWER ASSISTED SYSTEM POWER STEERING 2 Align the center of roll connector lt Ref to AB 17 ADJUSTMENT Roll Connector gt CAUTION Ensure that front wheel are set straight forward direction 3 Install the steering wheel and airbag module lt Ref to PS 19 INSTALLATION Steering Wheel gt WARNING Always refer to Air Bag System before per forming airbag module service lt Ref to AB 12 CAUTION Driver s Airbag Module gt and lt Ref to AB 12 INSTALLATION Driver s Airbag Mod ule gt PS 21 UNIVERSAL JOINT POWER ASSISTED SYSTEM POWER STEERING C INSPECTION Clean the disassembled parts with a cloth and check for wear damage or any other faults If necessary re pair or replace faulty parts Corrective action e Free play Swinging torque Yawing torque Looseness Yawing torque Replace if faulty Looseness G4M0089 Standard value of
295. n G sensor con nector terminals Connector amp terminal Go to step 10 Replace the G sensor lt Ref to ABS 23 G Sen sor gt B292 No 2 No 3 CHECK G SENSOR Is the voltage between 3 7 and to step 11 Replace the G Measure the voltage between G sensor con 4 1 V when G sensor is sensor Ref to nector terminals inclined forwards to 90 ABS 23 G Sen Connector amp terminal sor gt B292 No 2 No 3 CHECK G SENSOR Is the voltage between 0 5 and Go to step 12 Replace the G sensor lt Ref to ABS 23 G Sen sor gt Measure the voltage between G sensor con 0 9 V when sensor is Repair connector Go to step 13 is the voltage between 2 1 and 2 4 V when G sensor is hori zontal nector terminals inclined backwards to 90 Connector amp terminal 8292 No 2 No 3 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con nector between ABSCM amp H U and G sensor Is the same diagnostic trouble code as in the current diagno sis still being output CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code Replace the ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code Go
296. n Unos Read Diagnostic Trouble Code de CU Clear Memory ModE ABS Warning Light Illumination List of Diagnostics Trouble Code Diagnostics Chart with Diagnosis Diagnostics Chart with Subaru Select Monitor General Diagnostics Table Sev ad bu BASIC DIAGNOSTIC PROCEDURE ABS DIAGNOSTICS 1 Basic Diagnostic Procedure A PROCEDURE 1 WITHOUT SUBARU SELECT MONITOR CAUTION Remove foreign matter dust water etc from the ABSCM amp H U connector during removal and instal lation NOTE To check harness for broken wires or short circuits shake it while holding it or the connector When the ABS warning light illuminates read and record the diagnostic trouble code DTC indicated by ABS warning light Ye Neo Is unit that might influence the Go to step 2 Repair or replace each unit CHECK PRE INSPECTION 1 Ask the customer when and how the trouble ABS problem normal occurred using interview checklist Ref to ABS 6 Check List for Interview 2 Before performing diagnosis inspect the unit which might influence the ABS p
297. n a vise to make a measure ment At this time hold oil pump with the least possible force between two wood pieces Do not set outside of flow control valve or pulley on a vise otherwise outside or pulley might be deformed Select properly sized wood pieces 1 Play of pulley shaft On condition P 9 8 N 1 0 kgf 2 2 Ib Service limit Radial play Direction qm 0 4 mm 0 016 in or less S4M0439A 1 Dial indicator Axial play Direction lt gt Non TURBO model 0 4 mm 0 016 in or less TUHBO model 0 8 mm 0 031 in or less 54 0440 1 Dial indicator POWER ASSISTED SYSTEM POWER STEERING 2 Ditch deflection of pulley Service limit 1 0 mm 0 039 or less NOTE Read the value for one surface of V ditch and then the value for another off the dial S4M0441A 1 Dial indicator 3 Resistance to rotation of pulley Service limit Maximum load 9 22 N 0 94 kgf 2 07 Ib or less NOTE e Arather higher value may be indicated when pul ley starts turning e Measure the load during rotation and make a judgment S4M0442A 1 Spring balance PS 67 POWER ASSISTED SYSTEM POWER STEERING 3 HYDRAULIC PRESSURE CAUTION e Be sure to complete all items aforementioned in INSPECTION prior to measuring hydraulic pressure Otherwise pressure can not be mea sured correctly lt Ref to PS 74 INSPECTION General Diagnostic Table gt e Do not le
298. n and retighten if ineffective replace Leakage from surrounding of cast iron Damaged O ring Replace the oil pump ortion of oil pump 14 and 15 in ure iid Damaged gasket Replace the oil pump 5 Crack in oil tank Replace the oil tank Damaged cap packing Replace the cap Leakage from filler neck 18 Crack in root of filler neck Replace the oil tank High fluid level Adjust the fluid level parage Mom ol P Damaged oil seal Replace the oil seal cylinder of gearbox 19 in figure Leakage from control valve of gear Damaged packing or oil seal Replace the problem parts box 20 and 21 in figure Damage in control valve Replace the control valve NOTE Fluid level is specified at optimum position range for ordinary use Accordingly if the vehicle is used often under hard conditions such as on very rough roads or in mountainous areas fluid may bleed out from cap air vent hole This is not a problem If a customer complains strongly and is not likely to be satisfied with the leak age lower the fluid level to the extent that fluid will not bleed out under the conditions described and have the customer check the fluid level and its quality more frequency than usual PS 54 7 Pump REMOVAL 1 NON TURBO MODEL 1 Remove the ground terminal from battery 2 Remove the pulley belt cover 3 Loosen the oil pump pulley nut then remove the bolts which secure alternator 4
299. n in the figure After bleeding air from pressure gauges proceed to each check S4M0467A 1 Pressure gauge 2 Vacuum gauge 3 Adapter hose 4 Vacuum hose 5 Pedal force gauge Air tightness check 1 Start the engine and keep it running until a vac uum of 66 7 kPa 500 mmHg 19 69 inHg pointA is indicated on vacuum gauge Do not depress the brake pedal S4M0468A 1 Pressure gauge 2 Vacuum gauge 2 Stop the engine and watch the gauge If the vac uum drop range is less than 3 3 kPa 25 mmHg 0 98 inHg within 15 seconds after stopping the en gine the brake booster is functioning properly If defective the cause may be one of those listed below Check valve malfunction Leak from vacuum hose Leak from the shell jointed portion or stud bolt welded portion Damaged diaphragm e Leak from valve body seal and bearing portion Leak from plate and seal assembly portion Leak from poppet valve assembly portion Loaded air tightness check 1 Start the engine and depress the brake pedal with pedal force of 196 20 kgf 44 Ib Keep the engine running until a vacuum of 66 7 kPa 500 mmHg 19 69 inHg point B is indicated on vacu um gauge while the pedal is still depressed S4M0469A 1 Pressure gauge 2 Vacuum gauge 3 Pedal force gauge 4 Depress 2 Stop the engine and watch vacuum gauge If the vacuum drop range is less than 3 3 kPa 25 mmHg 0 98 inHg w
300. n the ignition switch to ON engine OFF nation meter lt Ref to IDI 11 Combination Meter Assembly gt CHECK ABS WARNING LIGHT BULB Is the ABS warning light bulb Go to step 3 Replace the ABS 1 Turn the ignition switch to OFF OK warning light bulb 2 Remove the combination meter lt Ref to IDI 11 3 Remove the ABS warning light bulb from Combination combination meter Meter Assembly gt CHECK BATTERY SHORT OF ABS WARN ING LIGHT HARNESS 1 Disconnect the connector B200 from con nector 74 2 Measure the voltage between connector B200 and chassis ground Connector amp terminal B200 19 Chassis ground CHECK BATTERY SHORT OF ABS WARN ING LIGHT HARNESS 1 Turn the ignition switch to ON 2 Measure the voltage between connector B200 and chassis ground Connector amp terminal B200 No 19 Chassis ground CHECK WIRING HARNESS 1 Turn the ignition switch to OFF 2 Install the ABS warning light bulb from com bination meter 3 Install the combination meter 4 Turn the ignition switch to ON 5 Measure the voltage between connector B200 and chassis ground Connector amp terminal B200 No 19 Chassis ground CHECK BATTERY SHORT OF ABS WARN ING LIGHT HARNESS 1 Turn the ignition switch to OFF 2 Measure the voltage between connector F74 and chassis ground Connector amp terminal F74 No 19 Chassis ground CHECK BA
301. nd hydraulic 8 Rear LH outlet T2 29 3 0 21 7 control unit 9 outlet 73 32 3 3 24 4 Front LH outlet 10 Bracket 5 Secondary inlet ABS 4 GENERAL DESCRIPTION ABS C CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during opera tion Remove contamination including dirt and corro sion before removal installation or disassembly Keep the disassembled parts in order and tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part in the vehicle is hot after running Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before disconnecting electrical connectors of sensors or units be sure to disconnect negative terminal from battery ABS 5 GENERAL DESCRIPTION ABS D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA150 CARTRIDGE Troubleshooting for electrical systems New apopted tool 22771AA030 SELECT MONITOR Troubleshooting for electrical systems KIT English 22771AA030 Without printer e German 22771AA070 Without printer French 22771 080 Without printer Spanish 22771 AA090 Without pri
302. nes glass nails etc out of the tread groove 3 Check the tires for deformation cracks partial wear Or wear CAUTION Replace the tire with a new one WT 8 FULL WHEEL WHEEL AND TIRE SYSTEM 7 Full Wheel Cap A REMOVAL Pry off the full wheel cap with a wheel cap remover inserted between openings in the cap B INSTALLATION Align the valve hole in the wheel cap with the valve on the wheel and secure the wheel cap by tapping four points by hand C INSPECTION 1 Check the wheels for missing wheel caps 2 Check the pawls of wheel caps for damage or bend 3 Check the wheel caps for cracks WT 9 GENERAL DIAGNOSTICS TABLE WHEEL AND TIRE SYSTEM 8 General Diagnostics Table A INSPECTION Front wheel shimmy WT 10 DIFFERENTIALS 1 22 Dillerential Gear s 3 CREUSE 4 R arDifferential soie bic i 5 Rear Differential Front Oil Seal 6 Rear Differential Side Oil Seal 7 Rear Differential 00 0 00 00 0 0100 8 General Diagnostic eie urea aide GENERAL DESCRIPTION DIFFERENTIALS 1 General Description A SPECIFICATIONS ao o MT AT Rear dferential type EF with LSD
303. ng 15 Apply the specified grease to the dust cover Dust cover S4M0166A 16 Install the dust cover on the valve assembly 17 Apply genuine grease to the pinion gear and bearing of valve assembly PS 34 STEERING GEARBOX 18 Install the gasket on the valve assembly Insert the valve assembly into the place while facing rack teeth toward pinion CAUTION Be sure to use a new gasket NOTE Do not allow packing to be caught when installing valve assembly 19 Tighten the bolts alternately to secure the valve assembly Tightening torque 25 N m 2 5 kgf m 18 1 ft Ib CAUTION Be sure to alternately tighten bolts 20 Apply grease to the sliding surface of sleeve and spring seat then insert the sleeve into the pin ion housing Fit the spring into the sleeve screw pack grease inside of screw then install the screw 4 1129 1 Adjusting screw 2 Spring 3 Sleeve POWER ASSISTED SYSTEM POWER STEERING 21 Install the lock washers and tighten the left and right tie rods into the rack ends On condition L Approximately 40 mm 1 57 in Tightening torque 78 8 0 kgf m 58 ft lb 54 0150 1 Tie rod 22 Bend the lock washer using a chisel CAUTION Be careful not to scratch rack when bending lock washer 1 S4M0384A 1 Lock washer PS 35 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 23 Rack and pinion backlash adjustment 1 Loo
304. nit ABSCM amp H U ABS 103 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS C DTC 21 OPEN OR SHORT CIRCUIT IN FRONT RIGHT ABS SENSOR CIRCUIT NOTE For the diagnostic procedure refer to DTC 27 lt Ref to ABS 105 DTC 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru Select Monitor gt D DTC 23 OPEN OR SHORT CIRCUIT FRONT LEFT ABS SENSOR CIRCUIT NOTE For the diagnostic procedure refer to DTC 27 lt Ref to ABS 105 DTC 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru Select Monitor gt E DTC 25 OPEN OR SHORT CIRCUIT IN REAR RIGHT ABS SENSOR CIRCUIT NOTE For the diagnostic procedure refer to DTC 27 lt Ref to ABS 105 DTC 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT Diagnostics Chart with Subaru Select Monitor gt ABS 104 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS F DTC 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT DIAGNOSIS Faulty ABS sensor Broken wire input voltage too high e Faulty harness connector TROUBLE SYMPTOM ABS does not operate ABS 105 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT oo gt 1 I 1 l i i i i SHIELD J
305. nk contact This may cause noise and stepped wear Reduce thickness of drive pinion height Backlash is too small on surfaces adjusting shim in order to move drive pin ion away from crown gear en G3M0098C G3M0098G DI 31 REAR DIFFERENTIAL DIFFERENTIALS TOOTH CONTACT PATTERN Contact patter Adjustment Toe contact This may cause chipping at toe ends Adjust as for flank contact Kk Contact area is small G3M0098D G3M0098G Heel contact This may cause chipping at heel ends Adjust as for face contact Contact area is small M G3M0098E 9 m Adjusting direction of drive pinion C Adjusting direction of crown gear DI 32 REAR DIFFERENTIAL DIFFERENTIALS 19 Install the rear cover and tighten bolts to spec ified torque CAUTION Securely connect the ground terminal of rear differential temperature sensor Tightening torque 29 3 0 kgf m 21 7 ft lb E INSPECTION Wash all the disassembled parts clean and exam ine them for wear damage or other defects Repair or replace defective parts as necessary 1 Crown gear and drive pinion e If abnormal tooth contact is evident find out the cause and adjust to give correct tooth contact at as sembly Replace the gear if excessively worn or in capable of adjustment e f crack score or seizure is evident replace as a set Slight damage of tooth can be corrected by oil stone or the like 2 Si
306. nside of gearbox Replace the bad parts of gear Creaking noise intermittent box While engine is running with Abnormal bearing for steering shaft Apply the grease or replace steering turned Generates when turning steering wheel with brake ser If the noise goes off when brake vice or parking applied is released it is normal Knocking When turning steering wheel in both direction with small angle repeatedly at engine ON or OFF Vane pump aeration Grinding noise continuous While engine is running Adjust or replace Replace two belts as a set Squeal squeak intermittent or continuous While engine is running Fluid aeration Sizzling noise continuous While engine is running Whine or growl continuous or intermittent While engine is running with without steering turned PS 76 GENERAL DIAGNOSTIC TABLE POWER ASSISTED SYSTEM POWER STEERING Possible cause Too low engine speed at start Adjust and instruct customers Fix the wrong part Damaged valve in oil pump gearbox Replace the oil pump bad parts of gearbox Retighten Vibration While engine is running with without steering turned suspension parts Looseness of play of steering PS 77 GENERAL DIAGNOSTIC TABLE POWER ASSISTED SYSTEM POWER STEERING 2 MEASUREMENT OF STEERING EFFORT
307. nsor i Diagnostics Chart with Diagnosis Connector gt Front left ABS sensor Abnormal ABS sensor Abnormal ABS sen Rear right ABS sensor sor signal 28 Rear left ABS sensor Any one of four Ref to ABS 46 DTC 24 ABNORMAL ABS SENSOR FRONT LH Diagnostics Chart with Diagnosis Connector gt lt Ref to ABS 46 DTC 26 ABNORMAL ABS SENSOR REAR Diagnostics Chart with Diagnosis Connector gt lt Ref to ABS 47 DTC 28 ABNORMAL ABS SENSOR REAR Diagnostics Chart with Diagnosis Connector gt lt Ref to ABS 53 DTC 29 ABNORMAL ABS SENSOR SIGNAL ANY ONE OF FOUR Diagnostics Chart with Diagnosis Connec tor gt lt Ref to ABS 57 DTC 31 ABNORMAL INLET SOLENOID VALVE CIRCUIT S ABSCM amp H U FRONT RH Diagnostics Chart with Diagnosis Connector gt lt Ref to ABS 61 DTC 32 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U FRONT RH Diagnostics Chart with Diagnosis Connector Ret to ABS 57 DTC 33 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U FRONT LH Diagnostics Chart with Diagnosis Connector Ret to ABS 61 DTC 34 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U FRONT LH Diagnostics Chart with Diagnosis Connector Ref to 5 57 DTC 35 ABNORMAL INLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR RH Diagnostics Chart with Diagnosis Connector Hef to ABS 61 DTC 36 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT S IN ABSCM amp H U REAR RH D
308. nter B2M3876 B2M3877 2 GENERAL PURPOSE TOOLS ABS 6 ABS CONTROL MODULE HYDRAULIC CONTROL UNIT ABSCM amp H U 2 ABS Control Module and draulic Control Unit AB SCM amp H U A REMOVAL 1 Disconnect the ground terminal from battery 2 Remove the air intake duct from engine compart ment to facilitate removal of ABSCM amp H U 3 Use an air gun to get rid of water around the AB SCM amp H U CAUTION The contact will be insufficient if the terminal gets wet 4 Pull off the lock of the ABSCM amp H U connector to remove it 5 Disconnect the connector from ABSCM amp H U CAUTION Be careful not to let water or other foreign mat ter contact the ABSCM amp H U terminal 6 Unlock the cable clip 7 Disconnect the brake pipes from ABSCM amp H U CAUTION Wrap the brake pipes with vinyl bag to avoid spilling brake fluid on vehicle body 8 Remove the ABSCM amp H U from engine compart ment CAUTION ABSCM amp H U cannot be disassembled Do not attempt to loosen the bolts and nuts Do not drop or bump the ABSCM amp H U e Do not turn the ABSCM amp H U upside down or place it on its side e Be careful to prevent foreign particles from getting into the ABSCM amp H U Apply a coat of rust preventive wax Nippeco LT or GB to bracket attaching bolt after tight ening Do not pull the harness when disconnecting connector ABS 7
309. o 1 No 3 CHECK OPEN CIRCUIT IN G SENSOR OUT PUT HARNESS AND GROUND HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Measure the resistance between ABSCM amp H U connector terminals Connector amp terminal F49 No 6 No 28 CHECK GROUND SHORT IN G SENSOR OUTPUT HARNESS 1 Disconnect the connector from G sensor 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 6 Chassis ground CHECK G SENSOR 1 Connect the connector to G sensor 2 Connect the connector to ABSCM amp H U 3 Turn the ignition switch to ON 4 Measure the voltage between G sensor con nector terminals Connector amp terminal B292 No 2 No 3 Is the voltage between 4 75 and 5 25 V Repair harness connector between G sensor and ABSCM amp H U Is the resistance between 4 3 and 4 9 kQ Repair harness connector between G sensor and ABSCM amp H U Is the resistance more than 1 MQ Is the voltage between 2 1 2 5 V when G sensor is hori zontal ABS 167 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK G SENSOR Is the voltage between 3 7 and Go to step 10 Replace the G Measure the voltage between sensor con 4 1 V when G sensor is sensor lt Ref to nector terminals inclined forwards to 90 ABS 23 G Sen C
310. o item 1 ABS SENSOR CN 60 mV 20 Standard output voltage 012 1 When it is 20 Hz Oscilloscope To terminal 33 nF 20 To terminal H4M1141A ADJUSTMENT Adjust the gap using spacer Part No 26755AA000 ABS 20 FRONT TONE WHEEL ABS 6 Front Tone Wheel A REMOVAL Refer to Front Drive Shaft because the front tone wheel is integrated with front drive shaft lt Ref to DS 32 REMOVAL Front Drive Shaft gt B INSTALLATION Refer to Front Drive Shaft because the front tone wheel is integrated with front drive shaft lt Ref to DS 32 INSTALLATION Front Drive Shaft gt C INSPECTION Visually check the tone wheels teeth 44 pieces for cracks or dents If necessary replace the tone wheel with a new one NOTE Replace the BJ assembly with a new one as sin gle unit if there is any defect found on the tone wheel since it is unitized with the BJ assembly of drive shaft ABS 21 REAR TONE WHEEL ABS 7 Rear Tone Wheel A REMOVAL Refer to Rear Drive Shaft because the rear tone wheel is integrated with hub lt Ref to DS 23 REMOVAL Rear Axle gt B INSTALLATION Refer to Rear Drive Shaft because the rear tone wheel is integrated with hub lt Ref to DS 26 INSTALLATION Rear Axle gt C INSPECTION Visually check the tone wheels teeth 44 pieces for cracks or dents If necessary replace the tone wheel with a new one ABS 22
311. ode as in the current diagno sis still being output Go to step 7 Go to step 8 CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code Replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary poor contact ABS 139 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS X DTC 44 ABS AT CONTROL CONTROLLED DIAGNOSIS Combination of AT control faults TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM F49 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT TURBO ENGINE MODEL NON TURBO ENGINE MODEL m 2 10 11 12 131 14115 24 19 20 21 BROO86 ABS 140 ae OE RECS Oe ee DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Sue Ns 1 CHECK BATTERY SHORT OF HARNESS Isthe voltage less than 1 V Go to step 2 Repair harness 1 Turn the ignition switch to OFF between TCM and 2 Disconnect two connectors from TCM ABSCM amp H U
312. oden block as shown in the figure to prevent damage to piston Do not apply excessively high pressure 4 1165 1 Place 30 mm 1 18 wide wooden block here 3 Remove the piston boot 4 Remove the piston seal from caliper body sylin der I C J Pe 5 Remove the guide pin and boot from caliper body 2 TURBO MODEL 1 Clean mud and foreign particles from the caliper body assembly and support CAUTION Be careful not to allow foreign particles to enter inlet at brake hose connector 2 Using a standard screwdriver remove the boot ring from piston B4M1164C 1 Boot ring 3 Remove the boot from piston end 4 Gradually supply compressed air via caliper body brake hose to force piston out CAUTION Place a wooden block as shown in the figure to prevent damage to piston B4M1165C 1 Place a 30 mm 1 18 in wide wooden block here BR 20 FRONT DISC BRAKE ASSEMBLY BRAKE 5 Remove the piston seal from caliper body cylin der B4M1172B 1 Piston pin 6 Remove the lock pin boot and guide pin boot D ASSEMBLY 1 NON TURBO MODEL 1 Clean the caliper body interior using brake fluid 2 Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Apply a coat of specified grease to the boot and fit in
313. oil to the filler plug level Ref to DI 17 Differ ential Gear Oil 01 20 ma a REAR DIFFERENTIAL DIFFERENTIALS C DISASSEMBLY To detect the real cause of trouble inspect the fol lowing items before disassembling Tooth contact of crown gear and pinion backlash Runout of crown gear at its back surface e Turning resistance of drive pinion 1 Set the ST on vise and install the differential as sembly to ST ST 398217700 ATTACHMENT 2 Drain the gear oil by removing plug 3 Remove the air breather cap NOTE Do not attempt to replace the air breather cap un less necessary S3M0530A Air breather cap B Rear cover 4 Remove the rear cover by loosening retaining bolts S3MO531A A Rear cover B Differential carrier 5 Make right and left side bearing retainers in or der to identify them at reassembly Remove the side bearing retainer attaching bolts set the ST to differential case and extract right and left side bearing retainers with a puller CAUTION Each shim which is installed to adjust the side bearing preload should be kept together with its mating retainer ST 398457700 ATTACHMENT S3M0532A 6 Pull out the differential case assembly from dif ferential carrier CAUTION Be careful not to hit the teeth against the case DI 21 REAR DIFFERENTIAL DIFFERENTIALS 7 When replacing the side bearing pull the bear in
314. ol Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code Is the voltage between 2 1 and Go to step 8 2 5 V when G sensor is hori zontal CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary poor contact CHECK OPEN CIRCUIT IN G SENSOR OUT PUT HARNESS AND GROUND HARNESS 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Measure the resistance between ABSCM amp H U connector terminals Connector amp terminal F49 No 6 No 28 CHECK GROUND SHORT OF HARNESS Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 28 Chassis ground Is the resistance between 4 3 and 4 9 KQ Repair harness connector between G sensor and ABSCM amp H U Is the resistance more than 1 MQ Repair harness between G sensor and ABSCM amp H U Replace ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Replace the G sensor Ref to ABS 23 G Sen sor gt CHECK G SENSOR 1 Remove the console box 2 Remove the G sensor from vehicle 3 Connect the connector to G sensor 4 Connect the connector to ABSCM amp H U 5 Turn the ignition switch to O
315. ole of stabilizer link FS 24 FRONT CROSSMEMBER FRONT SUSPENSION 8 Front Crossmember A REMOVAL 1 Disconnect the ground terminal from battery 2 Lift up the vehicle and remove the front tires and wheels 3 Remove the sub frame lt Ref to FS 16 RE MOVAL Sub Frame gt 4 Remove both stabilizer and jack up plate S4M0534A 1 Front stabilizer 2 Front crossmember 5 Disconnect the tie rod end from housing 6 Remove the front exhaust pipe Non turbo mod el Ref to EX SOHC 5 REMOVAL Front Ex haust Pipe 7 Remove the front transverse link from front crossmember and body E Xenia gt i 8 Remove the nuts attaching eiiis mount cush ion rubber to crossmember 9 Remove the steering universal joint Ref to PS 26 REMOVAL Steering Gearbox 10 Disconnect the power steering pipe from steer ing gear box 11 Lift the engine by approx 10 mm 0 39 in by using a chain block 12 Support the crossmember with a jack remove the nuts securing crossmember to body and lower crossmember gradually along with the steering gearbox CAUTION When removing the crossmember downward be careful that the tie rod end does not inter fere with SFJ boot 13 Remove the steering gearbox from crossmem ber B INSTALLATION 1 Install in the reverse order of removal CAUTION Always tighten the rubber bushing when wheels are in full contact with the ground and vehicle is cu
316. om the ABSCM amp H U terminal 2 Measure the signal voltage at connector B200 or F74 sensor 2 ground ABS 15 CONTROL MODULE SIGNAL ABS DIAGNOSTICS B SCHEMATIC 1 2 3 4 5 6 7 8 BATTERY O ABS control module and hydraulic control unit ABSCM amp H U ABS control module area Valve relay Motor relay Motor Front left inlet solenoid valve Front left outlet solenoid valve Front right inlet solenoid valve 9 10 11 12 13 14 15 16 Front right outiet solenoid valve Rear left inlet solenoid valve Rear left outlet solenoid valve Rear right inlet solenoid valve Rear right outlet solenoid valve Transmission control module only AT model Diagnosis connector Data link connector ABS 16 17 18 19 20 21 22 23 24 0108 ABS warning light Stop light switch Stop light G sensor Front left ABS sensor Front right ABS sensor Rear left ABS sensor Rear right ABS sensor CONTROL MODULE SIGNAL ABS DIAGNOSTICS C WAVEFORM ABS sensor Standard output voltage at 20 Hz B4M2526A ABS 17 SUBARU SELECT MONITOR ABS DIAGNOSTICS 6 Subaru Select Monitor A OPERATION 1 READ DIAGNOSTIC TROUBLE CODE DTC 1 Prepare the Subaru Select Monitor kit 2 Connect the diagnosis cable to Subaru Select Monitor 3 Insert the cartridge into Subaru Select Monitor lt Ref to ABS 10 SP
317. onnector amp terminal sor gt B292 No 2 No 3 CHECK G SENSOR Is the voltage between 0 5 and Go to step 11 Replace the G Measure the voltage between G sensor con 0 9 V when G sensor is sensor lt Ref to nector terminals inclined backwards to 90 ABS 23 G Sen Connector amp terminal Sor B292 No 2 No 3 CHECK POOR CONTACT IN CONNECTORS 15 there poor contact in con Repair the con Go to step 12 Turn the ignition switch to OFF nector between ABSCM amp H U and G sensor CHECK ABSCM amp H U Is the same diagnostic trouble the Go to step 13 1 Connect all connectors code as in the current diagno ABSCMA amp H U 2 Erase the memory sis still being output Ref to ABS 7 3 Perform the inspection mode ABS Control Mod 4 Read out the diagnostic trouble code ule and Hydraulic Control Unit ABSCM amp H U CHECK ANY OTHER DIAGNOSTIC TROU other diagnostic trouble Proceed with the A temporary poor BLE CODES APPEARANCE codes being output diagnosis corre contact sponding to the diagnostic trouble code a a LC 5 168 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS AF DTC 56 BATTERY SHORT IN G SENSOR CIRCUIT DIAGNOSIS e Faulty G sensor output voltage TROUBLE SYMPTOM ABS does not operate ABS 169 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS
318. ontrol Mod ule and Hydraulic Control Unit ABSCM amp H U Proceed with the diagnosis corre sponding to the diagnostic trouble code Go to step 6 Go to step 8 Repair harness between G sensor and ABSCM amp H U Go to step 9 Replace the G sensor Ref to ABS 23 G Sen sor gt CHECK OUTPUT OF SENSOR USING SE 15 the G sensor output on the LECT MONITOR monitor display between 2 1 1 Select Current data display amp Save on the 2 5 V when the G sensor select monitor is in horizontal position 2 Read the G sensor output in select monitor data display 15 there poor contact con nector between ABSCM amp H U and G sensor Is the same diagnostic trouble code as in the current diagno sis still being output CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary poor contact CHECK INPUT VOLTAGE OF G SENSOR 1 Turn the ignition switch to OFF 2 Remove the console box 3 Disconnect the G sensor from body Do not disconnect connector 4 Turn the ignition switch to ON 5 Measure the voltage between G sensor con nector terminals Connector amp terminal B292 N
319. oor contact con nectors between generator battery and ABSCM amp H U Is the same diagnostic trouble code as in the current diagno Sis still being output Are other diagnostic trouble codes being output ABS 136 Hepair the con Go to step 12 nector Replace the Go to step 13 ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code A temporary poor contact DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ABS 137 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS W DTC 44 ABS AT CONTROL NON CONTROLLED DIAGNOSIS e Combination of AT control faults TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT 7 22 T T B 855 112151411516 T zT Te To altata Ll el e fis 22 23 T2 3 4 878 18 rafts 16 17 18 DERI 22 23 5 138 TURBO ENGINE MODEL NON TURBO ENGINE MODEL SaaS 17 10111 15 17 8 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Ne Replace the Go to step 2 ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Go to step 3 Repair harness bet
320. operation is started by diagnosis connector HIGH means high voltage LOW means low voltage ABS 12 ABS SEQUENCE CONTROL ABS 4 CONDITIONS FOR COMPLETION OF ABS SEQUENCE CONTROL When the following conditions develop the ABS sequence control stops and ABS operation is re turned to the normal control mode 1 When the speed of at least one wheel reaches 10 km h 6 MPH 2 When terminal No 3 or No 6 are separated from diagnosis terminals When the select monitor is not used 3 When the brake pedal is released during se quence control and the braking lamp switch is set to OFF 4 When the brake pedal is depressed after the ig nition key is turned to ON and before ABS warning light goes out When the select monitor is not used 5 When the brake pedal is not depressed after the ignition key is turned to ON and within 0 5 seconds after ABS warning light goes out When the select monitor is not used 6 After completion of the sequence control 7 When malfunction is detected When the select monitor is used ABS 13 FRONT ABS SENSOR ABS 4 Front ABS Sensor 6 Remove the bolts which secure front ABS sen sor to housing and remove the front ABS sensor A REMOVAL CAUTION 1 Disconnect the ground terminal from battery Be careful not to damage the pole piece locat 2 Jack up the vehicle support it with rigid racks ed at tip of the sensor and teeth faces during re and remove the w
321. ostic trouble odes being output A temporary poor contact NOTE Check harnes and connector between AE SCM amp H U an ABS sensor Replace the ABS sensor Front Ref to ABS 14 Front ABS Sen Rear lt Ref s the resistance between 1 ind 1 5 CHECK ABS SENSOR 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABS sensor 3 Measure the resistance of ABS sensor con nector terminals Terminal Front RH No 1 No 2 Front LH No 1 No 2 Rear RH No 1 No 2 Rear LH No 1 No 2 30 to step 9 to ABS 18 Rear ABS Sensor ABS 107 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS CHECK BATTERY SHORT OF ABS SEN SOR 1 Disconnect the connector from ABSCM amp 2 Measure the voltage between ABS sensor and chassis ground Terminal Check Is the voltage less than 1 V Front RH No 1 4 Chassis ground Front LH 1 Chassis ground Rear RH No 1 Chassis ground Rear LH No 1 Chassis ground CHECK BATTERY SHORT OF ABS SEN SOR 1 Turn the ignition switch to ON 2 Measure the voltage between ABS sensor and chassis ground Terminal Front RH 1 Chassis ground Front LH No 1 Chassis ground Rear RH No 1 Chassis ground ves No _ Go to step 10 Replace the ABS
322. ot to damage the Airbag system wiring harness when servicing the center brake pipe e When removing the brake pipe make sure that it is not bent B INSTALLATION NOTE Airbag system wiring harness is routed near the center brake pipe CAUTION All Airbag system wiring harness and con nectors are colored yellow Do not use electri cal test equipment on these circuits Be careful not to damage the Airbag system wiring harness when servicing the center brake pipe When installing the brake pipe make sure that it is not bent After installing the brake pipe and hose bleed the air After installing the brake hose make sure that it does not touch the tire or suspension as sembly etc Brake pipe tightening torque 15 N m 1 5 kgf m 10 8 ft Ib C INSPECTION Ensure there are no cracks breakage or damage on pipes Check the joints for fluid leakage If any cracks breakage damage or leakage is found re pair or replace the pipe NOTE Use a mirror when inspecting the low visible part or back side BR 50 BRAKE PEDAL BRAKE 18 Brake Pedal A REMOVAL 1 MT MODEL 1 Remove the steering bolts 2 Raise the vehicle on hoist and remove the two bolts which secure steering unit to underside of body 3 Lower the vehicle to floor 4 Remove the instrument panel lower cover from instrument panel 5 Disconnect the following parts from pedal brack et e Operating rod of brake booste
323. ound 3 CHECK INPUT VOLTAGE OF ABS RELAY Is the voltage more than 10 V So to step 4 Repair open circuit 1 Instali the fuse harness 2 Remove the ABS relay between battery 3 Turn the ignition switch to ON and relay holder 4 Measure the voltage between ABS relay connector connector and chassis ground Connector amp terminal B264 No 2 Chassis ground Go to step 5 Repair harness connector between battery ignition switch and ABS relay Go to step 6 Repair open circuit between ABS CHECK INPUT VOLTAGE OF ABS RELAY relay and chassis Measure the voltage between ABS relay con ground GO to step 9 Is the voltage more than 10 V nector and chassis ground Connector amp terminal B264 No 1 Chassis ground CHECK GROUND CIRCUIT OF ABS RELAY 1 Turn the ignition switch to OFF 2 Measure the resistance between ABS relay connector and chassis ground Connector amp terminal 8264 No 3 Chassis ground CHECK ABS RELAY 1 Connect the battery to ABS relay terminal No 1 and 3 2 Measure the resistance between ABS relay terminals CHECK INPUT VOLTAGE OF ABSCM amp H U 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Run the engine at 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 1 Chassis ground CHECK GROUND CIRCUIT O
324. ound Connector amp terminal B225 No 5 Chassis ground 2 CHECK RELAY HOLDER Is the fuse blown out Replace fuse 3 CHECK INPUT VOLTAGE OF ABS RELAY s the voltage more than 10 V Go to step 4 Repair open circuit 1 Install the fuse in harness 2 Remove the ABS relay between battery 3 Turn the ignition switch to ON and relay holder connector Go to step 5 Repair harness connector between battery ignition switch and ABS relay Go to step 6 Repair open circuit between ABS relay and chassis ground Go to step 7 Replace the ABS 7 4 Measure the voltage between ABS relay Go to step 8 Repair harness connector between battery ABS relay and ABSCM amp H U connector and chassis ground Connector amp terminal Go to step 9 Repair the ABSCM amp H U ground harness Go to step 10 Replace the B264 2 Chassis ground CHECK INPUT VOLTAGE OF ABS RELAY ABSCM amp H U lt Ref to ABS 7 Repair the con nector Is the voltage more than 10 V Is the resistance less than 5 Q 1 Turn the ignition switch to OFF 2 Measure the resistance between ABS relay connector and chassis ground Connector amp terminal B264 No 3 Chassis ground CHECK ABS RELAY 1 Connect the battery to ABS relay terminal No 1 and 3 2 Measure the resistance between ABS relay terminals CHECK INPUT VOLTAGE OF ABSCM amp H
325. p 18 Replace the ABS sensor and ABSCM amp H U Front lt Ref to ABS 14 Front ABS Sensor gt Rear lt Ref to ABS 18 Rear ABS Sensor gt and Ref to ABS 7 ABS Con trol Module and Hydraulic Control Unit ABSCM amp H U gt Go to step 19 Repair harness between ABSCM amp H U and ABS sensor And replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Repair the con Go to step 20 nector Is the runout less than 0 05 mm 0 0020 in CHECK TONE WHEEL RUNOUT Measure the tone wheel runout CHECK GROUND SHORT OF ABS SENSOR 15 the resistance more than 1 1 Turn the ignition switch to ON 2 Measure the resistance between ABS sen sor and chassis ground Terminal Front RH No 1 Chassis ground Front LH No 1 Chassis ground Rear RH No 1 Chassis ground Rear LH No 1 Chassis ground CHECK GROUND SHORT OF HARNESS 1 Turn the ignition switch to OFF 2 Connect the connector to ABS sensor 3 Measure the resistance between ABSCM amp H U connector terminal and chassis ground Connector amp terminal DTC 21 F49 No 11 Chassis ground DTC 23 F49 No 9 Chassis ground DTC 25 F49 No 14 Chassis ground DTC 27 F49 No 7 Chassis ground CHECK POOR CONTACT IN CONNECTORS Is the resistance more than 1 MQ Is there poor contact in con nectors between ABSCM amp
326. pe for oil leaks Tightening torque Proportioning valve to brake pipe flare nut 15 1 5 kgf m 10 8 ft lb Proportioning valve to bracket 18 1 8 kgf m 13 0 ft lb C INSPECTION 1 Install the oil pressure gauges to measure the master cylinder fluid pressure front wheel brake fluid pressure and rear wheel cylinder fluid pres sure 2 Bleed air from the oil pressure gauges 3 Check the master cylinder fluid pressure and rear wheel cylinder fluid pressure The standard values are shown in the figure gt gt _ fluid pressure P3 When both circuits are normal Master cylinder fluid pressure P2 0067 4 For the oil pressure case of split point refer to SPECIFICATIONS lt Ref to BR 2 SPECIFICATIONS General De scription gt BR 43 BRAKE FLUID BRAKE 14 Brake Fluid A INSPECTION 1 Check that the brake fluid level remains between MIN and MAX If out of the specified range refill or drain fluid If fluid level becomes close to MIN refill fluid 2 Check the fluid for discoloration If fluid color has excessively changed drain the fluid and refill with new fluid B REPLACEMENT CAUTION To always maintain the brake fluid character istics replace the brake fluid according to maintenance schedule or earlier than that when used in severe condition e The FMVSS No 116 fresh DOT3 or 4 brake
327. phone or the wireless transmitter properly installed Are noise sources such as an antenna installed near the sensor harness Is the same diagnostic trouble code as in the current diagno sis still being output Are other diagnostic trouble codes being output ABS 131 ABS DIAGNOSTICS Repair the ABSCM amp H U ground harness Repair the con Go to step 3 nector Go to step 4 Properly install the car telephone or the wireless trans mitter Go to step 5 Go to step 6 Install the noise sources apart from the sensor har ness Replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code A temporary poor contact DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS U DTC 42 POWER SUPPLY VOLTAGE TOO LOW DIAGNOSIS e Power source voltage of the ABSCM amp H U is low TROUBLE SYMPTOM ABS does not operate WIRING DIAGRAM BATTERY SBF 1 OAD IQ GENERATOR SBF 4 IGNITION SWITCH RELAY lt 1121311 5878 2 sia 10 11 12113 24 15 161711811920 9 45116 19 4 25126 173 4201 27 30 7 11112113 18 2122 23 28 31132 33 38 11213145 6 7 8 9 10 1112 13 14 15 0085 ABS 132 DIAGNOSTICS CHART WITH SUBARU SELECT MONIT
328. posing shock absorbers be sure to bleed gas completely Also do not throw away in fire RS 6 GENERAL DESCRIPTION REAR SUSPENSION D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927380002 ADAPTER Used as an adapter for camber amp caster gauge f 4 2378 when measuring camber and caster 927720000 INSTALLER amp 1 28199AC000 PLATE REMOVER 2 28199AC010 BOLT 500014 927730000 INSTALLER amp REMOVER 500015 28099 100 REMOVER 500016 RS 7 Used for replacing front bushing Used for replacing rear bushing Used for removing DOJ GENERAL DESCRIPTION REAR SUSPENSION essa ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 92770000 INSTALLER amp Used for replacing lateral link bushing REMOVER SUO015 927690000 HELPER SOCKET Used for replacing lateral link bushing WRENCH 5 0015 2 GENERAL PURPOSE TOOLS TOOL NAME Alignment gauge Turning radius gauge Toe in gauge Used for toe in measurement Transmission jack Bearing puller RS 8 WHEEL ALIGNMENT REAR SUSPENSION 2 Wheel Alignment A INSPECTION NOTE The front and rear wheel alignment must be mea sured and or adjusted at once to obtain accuracy Measure and or adjust the rear wheel alignment to gether with the front Follow the procedure in FS section Wheel Alignment for measurement and or adjustment of wheel al
329. procedures refer to Air Bag System lt Ref to AB 12 CAUTION Driver s Airbag Module gt and lt Ref to AB 12 INSPECTION Driver s Airbag Module gt Inspection Corrective action Replace steering col umn assembly 570024 5 25 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 5 Steering Gearbox A REMOVAL 1 Set the vehicle on the lift 2 Disconnect the battery ground terminal 3 Loosen the front wheel nuts 4 Lift the vehicle and remove the front wheels 5 Remove the under cover 6 Remove the sub frame lt Ref to FS 16 RE MOVAL Sub Frame gt 7 Remove the front exhaust pipe assembly Non TURBO model lt Ref to EX SOHC 5 REMOVAL Front Exhaust gt WARNING Be careful exhaust pipe is hot 8 Using a puller remove the tie rod end from the knuckle arm after pulling off cotter pin and remov ing castle nut S4M0379A 1 Castle nut 2 Tie rod end 3 Knuckle arm 9 Remove the jack up plate and front stabilizer 1 Jack up plate 10 Remove the one pipe joint at the center of gear box and connect the vinyl hose to the pipe and joint Discharge the fluid by turning steering wheel fully clockwise and counterclockwise Discharge the fluid similarly from the other pipe 1 Pipe A 2 Pipe B 11 Remove the universal joint Ref to PS 20 REMOVAL Universal Joint 12 Disconnect the pipes C and D from the pipe of gearbox CAUTIO
330. r Electrical connectors for stop light switch etc 6 Remove the clevis pin which secures lever to push rod 7 Remove the nut which secures clutch master cylinder 8 Remove the steering assembly 9 Remove the accelerator pedal 10 Remove the bolts and nuts which secure pedal bracket 2 AT MODEL 1 Disconnect the ground cable from battery 2 Remove the instrument panel lower cover from instrument panel 3 Remove the clevis pin which secures brake ped al to brake booster operating rod Also disconnect the stop light switch connector 4 Remove the two bolts and four nuts which se cure brake pedal to pedal B INSTALLATION 1 Install in the reverse order of removal CAUTION If the cable clamp is damaged replace it with a new one Never fail to cover the outer cable end with boot Be careful not to kink the accelerator cable Always use new clevis pins 2 Adjust the clutch pedal Ref to CL 27 ADJUST MENT Clutch Pedal 3 Inspect after pedal installation lt Ref to BR 53 INSPECTION Brake Pedal BR 51 BRAKE PEDAL BRAKE C DISASSEMBLY 2 AT MODEL 1 MT MODEL 1 Remove the brake switch 1 Remove the brake switch lt Ref to BR 55 REMOVAL Stop Light Switch gt 2 Remove the clutch pedal lt Ref to CL 26 DISASSEMBLY Clutch Pedal gt 3 Remove the clutch master cylinder bracket 2 4 B4M2350A 1 Stopper 2 Bushing 3 Brake peda
331. r F74 from con nector B200 3 Turn the ignition switch to ON CHECK PROJECTION AT ABSCM amp H U 1 Turn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Check for broken projection at the ABSCM amp H U terminal Does the ABS warning light remain off Repair the front wiring harness Are the projection broken Replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic CHECK WIRING HARNESS Is the resistance more than 1 to step 6 Repair the har 1 Connect the connector to ABSCM amp H U MQ ness 2 Measure the resistance between connector F74 No 19 Chassis ground CHECK POOR CONTACT ABSCM amp H U 15 there poor contact in Repair the con Replace the CONNECTOR ABSCM amp H U connector nector ABSCM amp H U CHECK ABSCM amp H U Is the resistance more than 1 Goto step 4 Replace the Measure the resistance between ABSCM amp H U ABSCM amp H U terminals Ref to ABS 7 Terminals ABS Contro Mod No 22 No 23 ule and Hydraulic Control Unit ABSCM amp H U gt F74 and chassis ground lt Ref to ABS 7 CHECK WIRING HARNESS Is the resistance less than 0 5 Go to step 5 Repair the har Measure the resistance between connector Q ness F74 and chassis ground Connector amp terminal F74 No 19 Chassis ground Connector amp terminal ABS Control Mod ule and Hydraulic Control U
332. r dif ferential For potecting seal 4 2401 28099 100 4 2402 28099AC000 4 2403 2 GENERAL PURPOSE TOOLS disor removing all Joint rom arm DRIVE SHAFT REMOVER Used for removing rear drive shaft from rear dif ferential BOOT BAND PLI ERS Used for tightening front EBJ boot band Front axle housing side DS 13 PROPELLER SHAFT DRIVE SHAFT SYSTEM 2 Propeller Shaft A REMOVAL NOTE Before removing propeller shaft wrap metal parts with a cloth or rubber material In case of DOJ type before removing propeller shaft wrap metal parts installed at the rubber boot of center DOJ with a cloth or rubber material as shown in the figure Rubber boot may be damaged due to interference with adjacent metal parts while bending the DOJ during removal 7 ES it 1 Set the vehicle a lift 2 Disconnect the ground terminal from battery 3 Move the select lever or gear shift lever to N 4 Release the parking brake 5 Jack up the vehicle and support it with the safety stands rigid racks 6 Remove the rear exhaust pipe and muffler 7 Remove the rear differential protector If equipped 8 Remove the differential mount front cover 9 Remove the four bolts which hold propeller shaft to rear differential NOTE e Put matching mark on affected parts before re moval Remo
333. r tightening torque 8 N m 0 8 kgf m 5 8 ft Ib 5 Perform these steps for the brakes connecting to the secondary chamber of master cylinder first and then for the ones connecting to primary cham ber With all procedures completed fully depress the brake pedal and keep it in that position for ap proximately 20 seconds to make sure that there is no leak evident in the entire system 6 Check the pedal stroke While the engine is idling depress the brake pedal with a 490 50 kof 110 Ib load and measure the distance between the brake pedal and steering wheel With the brake pedal released measure the distance between the pedal and steering wheel again The difference between the two measure ments must be more than specified 54 0476 1 Steering wheel 2 Toe board Specified pedal stroke Without ABS 90 mm 3 54 in With ABS 95 mm 3 74 in When depressing brake pedal with a 490 N 50 kg 110 Ib load 7 If the distance is more than specified there is possibility that air is in the brake line Bleed the brake line until pedal stroke meets the specifica tion 8 Operate the hydraulic control unit in the se quence control mode With ABS Ref to ABS 11 ABS Sequence Control 9 Recheck the brake stroke 10 If the distance is more than specified there is a possibility air is in the inside of the hydraulic unit Repeat above steps 2 to 9 until pedal stroke meets the specification 11 Add
334. r within 60 until a slot in castle nut is aligned with the hole in ball stud end then insert the new cotter pin and bend it around castle nut 4 Install the front wheel C INSPECTION 1 Measure the play of ball joint by the following procedures Replace with a new one when the play exceeds the specified value 1 With 686 N 70 kgf 154 Ib loaded in the di rection shown in the figure measure dimension 01 2 With 686 70 kof 154 Ib loaded the op posite direction shown in the figure measure di mension 0 5 G4M0501 3 Calculate plays from the following formula 5 02 lt Q 4 When plays are larger than the following val ue replace with a new one FRONT BALL JOINT Specified play for replacement S Less than 0 3 mm 0 012 in 2 When the play is smaller than the specified val ue visually inspect the dust cover 3 The ball joint and cover that have been removed must be checked for wear damage or cracks and any defective part must be replaced 4 If the dust cover is damaged replace with a new ball joint FS 19 FRONT STRUT FRONT SUSPENSION 6 Front Strut 6 Remove the three nuts securing strut mount to body A REMOVAL 1 Remove the front wheel 2 Remove the bolt securing brake hose from strut 3 Scribe an alignment mark on the camber adjust ing bolt which secures strut to housing 4 Remove the bolt securing the ABS sensor har ness ema ao 500011 5
335. rance is outside specifications readjust 4 After confirmation of the ABS sensor clearance connect the connector to ABS sensor 5 Connect the battery ground terminal to battery C INSPECTION 1 ABS SENSOR 1 Check the pole piece of the ABS sensor for for eign particles or damage necessary clean the pole piece or replace the ABS sensor 2 Measure the ABS sensor resistance Standard 1020 2 CAUTION e If resistance is outside the standard value re place the ABS sensor with a new one e Check the marks on the harness to make sure that no distortion exists RH Light blue LH Brown NOTE Check the ABS sensor cable for discontinuity If necessary replace with a new one ABS 19 REAR ABS SENSOR ABS 2 SENSOR GAP Clearances sensor gaps should be measured one by one to ensure the tone wheel and speed sensor are installed correctly NOTE clearance is narrow adjust by using the spacer Part No 26755AA000 f clearance is wide check the outputted voltage then replace the ABS sensor or tone wheel if the outputted voltage is outside the specification ABS sensor clearance 0 7 1 2 mm 0 028 0 047 in Tone wheel ABS sensor Sensor gap 3 OUTPUT VOLTAGE Output voltage can be checked by the following method Install a resistor and condenser then ro tate the wheel about 2 75 km h 2 MPH or equiva lent NOTE Regarding terminal No please refer t
336. rb weight Tightening torque Transverse link bushing to crossmember 100 N m 10 2 kgf m 74 ft Ib Stabilizer to bushing 25 2 5 kgf m 18 1 ft Ib Tie rod end to housing 27 0 N m 2 75 kgf m 19 9 ft Ib Front cushion rubber to crossmember 85 N m 8 7 kgf m 62 7 ft Ib Universal joint to pinion shaft 24 N m 2 4 kgf m 17 4 ft Ib Crossmember to body 100 N m 10 2 kgf m 74 ft Ib 2 Purge air from the power steering system NOTE Check the wheel alignment and adjust if necessary C INSPECTION Check the crossmember for wear damage and cracks and correct or replace if defective FS 25 GENERAL DIAGNOSTIC TABLE FRONT SUSPENSION 9 General Diagnostic Table A INSPECTION 1 IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT Replace with proper parts 2 POOR RIDE COMFORT 2 Rocking of vehicle continues too long after run ning over bump and or hump 3 Large shock in bumping Possible causes Countermeasures 1 Large rebound shock 1 Breakage of coil spring 2 Overinflation pressure of tire Adjust 3 Improper wheel arch height Adjust or replace coil springs with new ones 4 Fault in operation of damper strut and or shock absorber 5 Damage or deformation of strut mount and or shock absorber mount 5j 6 Unsuitability of maximum and or minimum length of damper strut and or Replace with proper parts shock absorber 7 Deformation or loss of bushing 8 Deforma
337. re installing wheel on vehicle If wheel is installed and comes in contact with ground when axle nut is loose wheel bearings may be damaged e Be sure to tighten axle nut to specified torque Do not overtighten it as this may dam age wheel bearing 8 After tightening axle nut lock it securely DRIVE SHAFT SYSTEM C DISASSEMBLY 4 1 Place alignment marks on the shaft and outer race 2 Remove the SFJ boot band and boot CAUTION Be careful not to damage boot f 3 Remove the circlip from SFJ outer race using screwdriver 4 Remove the SFJ outer race from shaft assem bly 5 Wipe off grease CAUTION The grease is a special grease Do not confuse with other greases DS 33 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM 6 Place alignment mark on free ring and trunnion 11 Place the drive shaft in a vise between wooden blocks CAUTION Do not place drive shaft directly in the vise use wooden block 12 Raise the boot band claws by means of screw driver and hammer DN 7 Remove the free ring from trunnion CAUTION Be careful with the free ring position 8 Place alignment mark on trunnion and shaft B4M2220B Boot band claws 13 Cut and remove the boot CAUTION The boot must be replaced with a new one whenever it is removed 14 Thus disassembly of axle is completed but BJ cannot be disassembled CAUTION Be sure to wrap shaft
338. re kPa psi 981 10 142 or less Relief pres Non TURBO kPa kg cm psi 7 355 75 1 067 sure TURBO kPa psi 7 845 80 1 138 At standstill with engine idling on a con N kgf Ib 31 4 3 2 7 1 or less crete road At standstill with engine stalled on a concrete road kgf Ib 294 2 30 66 2 or less Recommended power steering fluid Manufacturer CALTEX CASTROL CASTROL F DEXRO MOBIL SHELL TEXACO Steering wheel effort Power steer ing system PS 3 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING CAUTION This table lists various clearances that must be correctly adjusted to ensure normal vehicle driving without interfering noise or any other faults 2 DOJ Shaft o on 7 Exhaust pipe Gearbox bolt 8 Side frame Hose and B 9 Cruise control pump Hose A and B 10 Pipe portion of hose A Pipe portion of hose B 11 AT cooling hose Joint 10 Emi PS AEE T 2 7 0 9 v8 11 2 1 570081 5 4 1 STEERING WHEEL AND COLUMN 1 2 3 4 5 GENERAL DESCRIPTION POWER ASSISTED SYSTEM POWER STEERING Bushing Knee protector Steering shaft Steering roll connector Column cover 6 Steering wheel 7 Airbag module 8 Lower steering wheel cover PS 5 11 2 19 14 5
339. re the brake hose is not twisted 5 Temporarily tighten the flare nut to connect brake pipe and hose 6 Fix the brake hose with clamp at wheel apron bracket 7 While holding the hexagonal part of brake hose fitting with a wrench tighten the flare nut to the specified torque Tightening torque Brake pipe flare nut 15 N m 1 5 kgf m 10 8 ft Ib 8 Bleed air from the brake system Ref to 46 Air Bleeding BR 48 BRAKE HOSE BRAKE 2 REAR BRAKE HOSE C INSPECTION 1 Pass the brake hose through the hole of bracket Ensure there are no cracks breakage or damage and lightly tighten the flare nut to connect brake on hoses Check the joints for fluid leakage If any hose cracks breakage damage or leakage is found re 2 Insert the clamp upward to fix brake hose pair or replace the hose 3 While holding the hexagonal part of brake hose fitting with a wrench tighten the flare nut to the specified torque Tightening torque Brake pipe flare nut 15 N m 1 5 kgf m 10 8 ft lb 1 Brake hose clip 2 Brake hose 3 Brake pipe 4 Bleed air from the brake system lt Ref to BR 46 Air Bleeding gt BR 49 BRAKE PIPE BRAKE 17 Brake Pipe A REMOVAL NOTE Airbag system wiring harness is routed near the center brake pipe CAUTION All Airbag system wiring harness and con nectors are colored yellow Do not use electri cal test equipment on these circuits Be careful n
340. rear wheel cap and wheels NOTE Axle nut need not be removed 3 Remove the ABS sensor clamps and parking brake cable bracket 4 Disconnect the stabilizer link from the lateral link 5 Remove the bolts which secure lateral link as sembly to the rear housing 6 Remove the bolts which secure trailing link as sembly to the rear housing 7 Remove the DOJ from rear differential using ST ST 28099PA100 DRIVE SHAFT REMOVER NOTE The side spline shaft circlip comes out together with the shaft CAUTION Be careful not to damage the side bearing re tainer Always use bolt as shown in figure as supporting point for ST during removal ST 28099PA100 DRIVE SHAFT REMOVER S4M0373A 1 Side bearing retainer 8 Remove the DOJ and BJ or boots from the drive shaft lt Ref to DS 41 DISASSEMBLY Rear Drive Shaft gt 9 Install the DOJ and BJ or boots to the drive shaft lt Ref to DS 42 ASSEMBLY Rear Drive Shaft gt DS 44 REAR DRIVE SHAFT BOOTS DRIVE SHAFT SYSTEM 10 Using ST install the DOJ into differential 14 Connect the rear housing assembly to the trail ST 28099PA090 SIDE OIL SEAL PROTEC ing link assembly and tighten the self locking nut TOR 15 Connect the rear housing assembly to the lat eral link assembly and tighten the self locking nut 16 Connect the stabilizer link to the lateral link 17 Install the ABS sensor clamps and parking brake cable bracket 11 Insert
341. rforming diagnosis inspect the unit which might influence the ABS problem Ref to ABS 9 INSPECTION General Descrip tion CHECK INDICATION OF TROUBLE CODE DISPLAY 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 SUBARU SELECT MONITOR to ON NOTE If the communication function of the select monitor cannot be executed normally check the communication circuit Ref to ABS 96 COMMUNICATION FOR INITIALIZING IM POSSIBLE Diagnostics Chart with Subaru Se lect Monitor 4 Read the diagnostic trouble code DTC lt Ref to ABS 19 READ CURRENT DATA OPERATION Subaru Select Monitor gt 5 Record diagnostic trouble codes DTC and frame data PERFORM THE GENERAL DIAGNOSTICS 15 no diagnostic trouble code 1 Inspect using General Diagnostics Table designated and ABS lt Ref to ABS 183 General Diagnostics Table gt warning light goes out after 2 Perform the clear memory mode Ref to turning on ABS 19 CLEAR MEMORY MODE OPERA TION Subaru Select Monitor 3 Perform the inspection mode Ref to ABS 21 Inspection Mode 4 Calling up the diagnostic trouble code DTC Ref to ABS 18 READ DIAGNOSTIC TROU BLE CODE DTC OPERATION Subaru Is the corresponding trouble encoding Complete the diagnosis Select Monitor 5 4 Go to step 2 Repair or replace eac
342. ring cone B3M1912 DI 12 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507701 DIFFERENTIAL e Used for adjusting pinion height CARRIER GAUGE B3M1913 398527700 PULLEY ASSY B3M1914 399527700 PULLER SET gt B3M1915A 398227700 WEIGHT Used for installing side bearing B3M1916 DI 13 e Used for removing front oil seal e Used for removing side bearing cup T type Used for extracting side bearing cone 1 BOLT 899521412 2 PULLER 399527702 3 HOLDER 399527703 4 ADAPTER 398497701 5 BOLT 899520107 6 NUT 021008000 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28099PA090 OIL SEAL PROTEC e Used for installing rear drive shaft into rear dif B3M1917 TOR ferential 398237700 e For protecting oil seal Used for installing side bearing B3M1918 DRIVE SHAFT REMOVER Used for removing rear drive shaft from rear differential PULLEY ASSY Used for removing companion flange B3M1930 DI 14 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION 899874100 INSTALLER Used for installing companion flange B3M1931 DI 15 GENERAL DESCRIPTION DIFFERENTIALS 2 GENERAL PURPOSE TOOLS Pae Side bearing retainer DI 16 DIFFERENTIAL
343. rmal wear of tire Unbalance of remained grooves Unbalance of tire pressure Front alignment Improper or unbalance caster Improper or unbalance toe in Loose connection of suspension Others Damaged joint assembly e Unbalanced height One sided weight 5 Measure steering effort lt Ref to PS 74 INSPECTION Gen Adjust or replace eral Diagnostic Table gt 1 If the tires and or rims are wider the load to power steering system is the more Accordingly in a condition for example before fluid warms up relief valve may work before maximum turning angle In this case steering effort may be heavy When the mea sured hydraulic pressure is normal there is no abnormal thing 2 In cold weather steering effort may be heavy due to increased flow resistance of cold fluid After warming up engine turn the steering wheel from stop to stop several times to warm up fluid Then if steering effort reduces normally there is no abnormal thing 3 In cold weather or with insufficient warm up of engine steering effort may be heavy due to excessive drop of idling when turn ing steering wheel In this case it is recommended to start the vehicle with increasing engine speed than usual Then if steering effort reduces normally there is no abnormal thing e nie Adjust or instruct customer Reform or replace Fix or replace Adjust or retighten Vehicle leads to one side or
344. rn spring 6 Silencer 10 Plunger valve 3 Reaction disc 7 Operating rod 11 Diaphragm plate 4 Key 8 Poppet valve 12 Valve return spring BR 11 GENERAL DESCRIPTION BRAKE 8 BRAKE PEDAL MT Model B4M2345A 1 Stopper 12 Clutch clevis pin 23 Clutch switch Starter interlock 2 Bushing 13 Assist rod A 24 Clutch switch With cruise control 3 Spring pin 14 Clip 25 Stop light switch 4 Snap pin 15 Assist spring 26 Pedal bracket 5 Brake pedal pad 16 Assist bushing 27 Clutch master cylinder bracket 6 Brake pedal 17 Assist rod B 28 Lever 7 pin 18 Spring S 8 Brake pedal spring 19 RodS Tightening torque N m kgf m ft Ib 9 Clutch pedal pad 20 Bushing S T1 8 0 8 5 8 10 Clutch pedal 21 O ring T2 18 1 8 13 0 11 Bushing C 22 Clip BR 12 GENERAL DESCRIPTION BRAKE AT Model 1 2 3 4 5 Stopper Bushing Pedal bracket Stop light switch Snap pin 6 7 8 9 Brake pedal pad Brake pedal Clevis pin Brake pedal spring BR 13 7 6 0007 Tightening torque N m kgf m ft Ib 8 0 8 5 8 2 18 1 8 13 0 T3 29 3 0 21 7 GENERAL DESCRIPTION BRAKE C CAUTION Wear working clothing including cap protec tive goggles and protective shoes during opera tion e Remove contamination including dirt and corro sion before removal installation or disassembly
345. rn the ignition switch to OFF 2 ABSCM amp H U 2 Measure the resistance between ground harness ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 23 Chassis ground ABS 71 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS CHECK POOR CONTACT IN CONNECTORS CHECK ABSCM amp H U 1 Connect connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Is there poor contact in con nectors between generator battery and ABSCM amp H U Is the same diagnostic trouble code as in the current diagno sis still being output Are other diagnostic trouble codes being output ABS 72 Repair the con 30 to step 12 nector Replace the Go to step 13 ABSCM amp H U Ref to ABS 7 ABS Contro Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code A temporary poor contact DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS ABS 73 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS W DTC 44 A COMBINATION OF AT CONTROL ABNORMAL DIAGNOSIS Combination of AT control faults TROUBLE SYMPTOM e ABS does not operate WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT TURBO ENGINE MODEL NON TURBO ENGINE MODEL 1
346. rning toe in adjusting bolts of rear suspension equally in the same direction 2 When one rear wheel is adjusted in a toe in di rection adjust the other rear wheel equally in toe out direction in order to make the thrust angle ad justment Iunii 0 ttim 54 0350 1 Center line of loci front axle 2 Center line of loci rear axle NOTE Thrust angle refers to a mean value of left and right rear wheel toe angles in relation to the vehicle body center line Vehicle is driven straight in the thrust angle direction while swinging in the oblique direction depending on the degree of the mean thrust angle B4M0193B 1 Front 2 Thrust angle 3 Body center line FS 14 WHEEL ALIGNMENT FRONT SUSPENSION ES PE TS OT TT TE LI ET ET TE ET Thrust angle r a 2 a Right rear wheel toe in angle Left rear wheel toe in angle NOTE Here use only positive toe in values from each wheel to substitute for and in the equation B4M0194B 1 Front 2 Body center line FS 15 SUB FRAME FRONT SUSPENSION 3 Sub Frame B INSTALLATION A REMOVAL m the reverse order of removal 1 Lift up the vehicle 2 Remove the under cover 3 Remove the bolt cover Tightening torque T1 34 N m 3 5 kgf m 25 ft Ib 2 55 5 6 kgf m 41 ft Ib T3 71 N m 7 2 kgf m 52 ft Ib 14 105 N m 10 7 kgf m 77 ft Ib Replace the M12 bolt with a new one
347. roblem Ref to ABS 9 INSPECTION General Descrip tion CHECK INDICATION OF DIAGNOSTIC TROUBLE CODE DTC Calling up diagnostic trouble code DTC Ref to ABS 20 Read Diagnostic Trouble Code DTC gt Is the diagnostic trouble code to step 3 Inspect using diag nostic chart for ABS warning light failure Ref to ABS 29 Diagnos DTC readable tics Chart with Diagnosis Con nector NOTE Call up diagnostic trouble code DTC again after inspect ing ABS warning light lt Ref to ABS 20 Read Diagnos tic Trouble Code DTC gt Is only the start code issued to step 4 Go to step 5 CHECK DIAGNOSTIC TROUBLE CODE DTC NOTE Record all diagnostic trouble codes DTC PERFORM THE GENERAL DIAGNOSTICS 15 only the start code issued the Go to step 5 1 Inspect using General Diagnostics Table lt Ref to ABS 183 General Diagnostics Table gt 2 Perform the clear memory mode lt Ref to ABS 22 WITHOUT SUBARU SELECT MONI TOR OPERATION Clear Memory Mode gt 3 Perform the inspection mode lt Ref to ABS 21 Inspection Mode gt Calling up the diagnostic trouble code DTC lt Ref to ABS 20 Read Diagnostic Trouble Code DTC gt ABS 2 BASIC DIAGNOSTIC PROCEDURE ABS DIAGNOSTICS PERFORM THE DIAGNOSIS is only the start code issued Complete the inspect using 1 Inspect using Diagnostics Chart wi
348. rom back plate NOTE Remove the support only when replacing it or the rotor It need not be removed when servicing the caliper body assembly 8 Clean mud and foreign particles from the caliper body assembly and support CAUTION Be careful not to allow foreign particles to enter inlet at brake hose connector B INSTALLATION 1 Install the disc rotor on hub 2 Install the support on back plate Tightening torque 53 5 4 kgf m 39 1 ft lb CAUTION Always replace the pads for both the left and right wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the pad wears down to such an ex tent that the end of the wear indicator contacts the disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard re place the pad e Replace the pads if there is oil or grease on them 3 Apply a thin coat of Molykote AS880N Part No 26298ACO000 to the frictional portion between pad and pad clip 4 Install the pads on support 5 Install the caliper body on support Tightening torque 37 N m 3 8 kgf m 27 5 ft Ib 6 Connect the brake hose Tightening torque 18 1 8 kgf m 13 0 ft Ib CAUTION e The brake hose must be connected without any twist e Replace the brake hose gaskets with new ones 7 Bleed air from the brake system Ref to BR 46 Air Bleeding BR 27 REAR DISC BR
349. rouble Function of clearing diagnostic trouble code DTC and freeze frame data code DTC appears on the select moni tor display A specified period of time proceeding diagnostic trouble code DTC appears on the select monitor display AE ANALOG DATA ARE DIS PLAYED Display screen Contents to be monitored Wheel speed detected by the Front Right FR wheel speed ABS sensor is displayed in km h or mile h Wheel speed detected by the Front Left FL wheel speed ABS sensor is displayed in km h or mile h Wheel speed detected by the Rear Right RR wheel speed ABS sensor is displayed in km h or mile Wheel speed detected by the Rear Left RL wheel speed ABS sensor is displayed in km h or mile h Stop light switch Stop light switch monitor voltage is dis played Refers to vehicle acceleration detecting by the analog G sensor It appears on the select monitor display in volts G sensor output voltage AF ON OFF DATA ARE DISPLAYED Display screen Contents to be monitored Stop light switch Stop light switch signal Valve relay signal Valve relay signal Motor relay signal Motor relay signal ABS operation signal from ABS con ABS TOM trol module to TCM ABS warning light ABS warning light Valve relay monitor Valve relay operation monitor signal Motor relay monitor Motor relay operation
350. round Front LH No 1 Chassis ground Rear No 1 Chassis ground Rear LH No 1 Chassis ground 5 the resistance more than 1 MO ABS 44 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS CHECK GROUND SHORT OF HARNESS 1 Turn the ignition switch to OFF 2 Connect the connector to ABS sensor 3 Measure the resistance between ABSCM amp H U connector terminal and chassis ground Connector amp terminal DTC 21 F49 No 11 Chassis ground DTC 23 F49 No 9 Chassis ground 25 F49 No 14 Chassis ground DTC 27 F49 No 7 Chassis ground 115 there poor contact in con nectors between ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Is the resistance more than 1 MQ and ABS sensor Is the same diagnostic trouble code as in the current diagno sis still being output Are other diagnostic trouble codes being output ABS 45 Yes Go to step 12 Repair the con nector Replace the ABSCM amp H U lt Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code Repair harness between ABSCM amp H U and ABS sensor Replace ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Un
351. rt with Subaru Select Monitor gt M DTC 33 FRONT LEFT INLET VALVE MALFUNCTION NOTE For the diagnostic procedure refer to DTC 37 lt Ref to ABS 121 DTC 37 REAR LEFT INLET VALVE MAL FUNCTION Diagnostics Chart with Subaru Select Monitor gt N DTC 35 REAR RIGHT INLET VALVE MALFUNCTION NOTE For the diagnostic procedure refer to DTC 37 lt Ref to ABS 121 DTC 37 REAR LEFT INLET VALVE MAL FUNCTION Diagnostics Chart with Subaru Select Monitor gt O DTC 37 REAR LEFT INLET VALVE MALFUNCTION DIAGNOSIS Faulty harness connector e Faulty inlet solenoid valve TROUBLE SYMPTOM ABS does not operate ABS 121 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY O IGNITION SWITCH RELAY C Ss ee 17 314 10 11 15 17118 12102 512 0085 5 122 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS Step Check Yes No CHECK INPUT VOLTAGE OF RELAY HOLD Is the voltage more than 10 V So step 2 Repair open circuit ER in harness 1 Turn the ignition switch to OFF oetween battery 2 Remove the fuse and relay holder 3 Measure the voltage between ABS relay connector connector and chassis ground Connector amp terminal B225 5 Chassis gr
352. rts Loosened linkage or play of steering or suspension Loos te Retighten or replace ened tightening of joint or steering column Sound generates from the inside of gearbox or oil pump gearbox or oil pump Excessive backlash Loosened lock nut for adjusting backlash Loosened tightening or play of tie rod tie rod end Retighten or replace Inspect and retighten the fluid line connection Refill the fluid and vent air Vane pump seizing Replace oil pump Pulley bearing seizing of oil pump Replace oil pump Folded hose flat pipe Maladjustment of puiley belt Damaged or charged pulley belt Unequal length of pulley belts Run out or soilage of V groove surface of oil pump pulley Clean or replace Fix the wrong part causing aera tion Replace the fluid and vent air Damaged pipe of gearbox Replace the pipe Abnormal inside of hose or pipe Rectify or replace Flat hose or pipe Abnormal inside of oil tank Removed oil tank cap Install cap veiste continuous Abnormal pipe of gearbox or abnormal inside of hose Replace the bad parts of gearbox While engine is running or hose Loosened installation of oil pump oil pump bracket Replace the oil pump hose if the Abnormal inside of oil pump hose noise can be heard when running as well as stand still xx Remove the power steering pul Torque converter growl air conditioner compression grow ley belt and confirm M Abnormal i
353. ru Select Monitor high u output high u output PUT Diagnostics Chart with Subaru Select Monitor Detection of G sensor Detection of G sensor Stick Stick Diagnostics Chart with Subaru Select Monitor NOTE High means high friction coefficient against road surface ABS 27 LIST OF DIAGNOSTICS TROUBLE CODE DTC ABS DIAGNOSTICS ABS 28 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS 12 Diagnostics Chart with Diagnosis Connector A ABS WARNING LIGHT DOES NOT COME ON DIAGNOSIS ABS warning light circuit is open or shorted TROUBLE SYMPTOM e When the ignition switch is turned ON engine OFF ABS warning light does not come on ABS 29 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY SBF 3 SBF 1 CN e PIS 387 4 IGNITION SWITCH lt gt AX RELAY HOLDER TURBO ENGINE MODEL NON TURBO ENGINE MODEL No 18 COMBINATION METER DIAGNOSIS A TERMINAL roo 242 90 a ae 474 112 312 181415 6 8 9 03 osos 101102 D4 D5 D4 RELAY HOLDER 0083 5 30 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS No _ 1 CHECK IF OTHER WARNING LIGHTS TURN Do other warning lights turn Go to step 2 Repair the combi ON Tur
354. rvoir tank PS 71 POWER STEERING FLUID POWER ASSISTED SYSTEM POWER STEERING 9 Power Steering Fluid A SPECIFICATION DEXRON III B INSPECTION 1 Check the power steering fluid for deterioration or contamination If the fluid is highly deteriorated or contaminated drain it and refill with new fluid 2 Check the joints and units for oil leakage If any oil leaks are found repair or replace the applicable part 3 Inspect the fluid level on flat and level surface with engine OFF by indicator of reservoir tank If the level is at lower point or below add fluid to keep the level in the specified range of the indica tor If at upper point or above drain the fluid by us ing a syringe or the like 1 Check at temperature 20 C 68 F on reser voir surface of oil pump read the fluid level on the COLD side 2 Check at temperature 80 C 176 F on res ervoir surface of oil pump read the fluid level on the side HOT MAX COED MeV COLD MIN 4 1674 INSTALLATION 1 Set ST on the top of reservoir tank and fill it about half way with the specified fluid ST 34199AE040 OIL CHARGE B4M1673A 2 Continue to turn the steering wheel slowly from lock to lock until the bubbles stop appearing in the tank while keeping the fluid at that level 3 In case air is absorbed to deliver bubbles into piping because the fluid level is lower leave it about half an hour and then
355. s of the tire And also inspect to rotate the wheel smoothly 2 Inspect the lean of axis direction using a dial gauge Replace the hub bearing if the load range exceed the limitation Limit Maximum 0 05mm 0 0020 Ded oN Pa gt Rl 2 ii Nel 7 M 3 Inspect the removed parts for wear and damage If defective replace with new ones CAUTION e f bearing is faulty replace it as the bearing set e Be sure to replace oil seal at every overhaul eceles A H4M1002C Replace as a set DS 22 DRIVE SHAFT SYSTEM 4 Rear Axle A REMOVAL 1 DISC BRAKE 1 Disconnect the ground cable from battery 2 Jack up the vehicle and remove the rear wheel cap and wheels CAUTION Be sure to loosen and retighten the axle nut af ter removing wheel from vehicle Failure to fol low this rule may damage wheel bearings 3 Unlock the axle nut 4 Remove the axle nut using a socket wrench 5 Return the parking brake lever and loosen the adjusting nut 5 7 D sae 0054 1 Parking brake lever 2 Lock nut 3 Adjusting nut 6 Remove the disc brake caliper from the back plate and suspend it from strut using a piece of wire 7 Remove the disc rotor from the hub NOTE If disc rotor seizes up within hub drive it out by in stalling an 8 mm bolt into bolt hole in disc rotor 8 Disconnect the parkin
356. s adjustment correct it by turning the right and left tie rods in the same direction by the same turns PS 46 PIPE ASSEMBLY 6 Pipe Assembly A REMOVAL 1 Disconnect the battery ground terminal 2 Lift the vehicle and remove the jack up plate 1 Jack up plate 3 Remove one pipe joint at the center of gearbox and connect a vinyl hose to the pipe and joint Dis charge the fluid by turning steering wheel fully clockwise and counterclockwise Discharge the flu id similarly from the other pipe CAUTION Improper removal and installation of parts often causes fluid leak trouble To prevent this clean the surrounding portions before disassembly and reassembly and pay special attention to keep dirt and other foreign matter from mating surfaces S4M0381A POWER ASSISTED SYSTEM POWER STEERING 4 Remove the clamp E from pipes C and D S4M0437A 1 Return hose 2 Pressure hose 3 Clamp E 4 PipeC 5 Pipe D 5 Disconnect the pipe C D from the pipe on the gearbox side CAUTION e When disconnecting pipe C D use two wrenches to prevent deformities e careful to keep pipe connections free from foreign matter 54 0382 1 Pipe 2 Pipe D PS 47 PIPE ASSEMBLY POWER ASSISTED SYSTEM POWER STEERING 6 Non TURBO model 1 Remove the air intake duct lt Ref to IN SO HC 7 REMOVAL Air Intake Duct gt 2 Remove the bolt A 3 Disconnect t
357. sary C INSPECTION Check the removed parts for wear damage and cracks and correct or replace if defective RS 19 GENERAL DIAGNOSTIC TABLE REAR SUSPENSION 8 General Diagnostic Table A INSPECTION 1 IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT 2 POOR RIDE COMFORT 1 Large rebound shock 2 Rocking of vehicle continues too long after running over bump and or hump 3 Large shock in bumping Possible causes Countermeasures 1 Breakage of coil spring 2 Overinflation pressure of tire Adjust 3 Improper wheel arch height Adjust or replace coil springs with new ones 4 Fault in operation of damper strut and or shock absorber 5 Damage deformation of strut mount and or shock absorber mount 6 Unsuitability of maximum and or minimum length of damper strut and or Replace with proper parts shock absorber 7 Deformation or loss of bushing 8 Deformation or damage of helper in strut assembly and or shock Replace absorber 9 Oil leakage of damper strut and or shock absorber 3 NOISE Possible causes Countermeasures 1 Wear or damage of damper strut and or shock absorber component parts 2 Loosening of suspension link installing bolt Retighten to the specified torque 3 Deformation or loss of bushing 4 Unsuitability of maximum and or minimum length of damper strut and or Replace with proper parts shock absorber 5 Breakage of col spring 6
358. se the parking brake 5 Remove the oil drain plug and drain gear oil A Filler plug B Drain plug 6 Install the oil drain plug NOTE Apply fluid packing to drain plug Tightening torque 49 N m 5 0 kgf m 36 2 ft Ib 7 Remove the rear exhaust pipe and muffler 8 Remove the rear differential protector If equipped 9 Remove the propeller shaft from body Ref to 05 14 REMOVAL Propeller Shaft 10 Remove the self locking nut while holding com panion flange with ST ST 498427200 FLANGE WRENCH 11 Extract the companion flange using ST PULLEY ASSY ST 399703602 12 Remove the oil seal using ST ST 499705401 PULLER ASSY 13 Fit a new oil seal using ST ST 498447120 DRIFT 14 Install the companion flange NOTE Use a plastic hammer to install companion flange DI 35 REAR DIFFERENTIAL FRONT OIL SEAL DIFFERENTIALS 15 Tighten the self locking nut within the specified torque range so that the turning resistance of com panion flange becomes the same as that before re placing oil seal ST 498427200 FLANGE WRENCH NOTE Use a new self locking nut Tightening torque 181 4 18 50 kgf m 133 8 ft lb s 16 Reassembling procedure hereafter is the re verse of the disassembling 17 Fill the differential carrier with gear oil to the fill er plug level Ref to DI 17 Differential Gear Oil 01 36 REAR DIFFERENTIAL SIDE OIL SEAL DIFFERENTIALS
359. seal Always tighten the rubber bushing location when wheels are in full contact with the ground and vehicle is curb weight Tighten the nut when installing adjusting bolt Replace the self locking nut and DOJ circlip with new ones NOTE Check the wheel alignment adjust if necessary DISASSEMBLY Using ST press the bushing out of place NOTE e Using the following table as a guide verify the type of bushings Select the ST according to the type of bushings used Bushing ST INSTALLER amp REMOVER SET Bushing A 927700000 Bushing B 927690000 Bushing C 927700000 RS 16 LATERAL LINK REAR SUSPENSION D ASSEMBLY 1 Using ST press the bushing into place CAUTION Select the ST according to the type of bushings used NOTE e Use the same ST as that used during disassem bly e f it is difficult to press the bushing into trailing link apply water diluted TIRE LUBE to the inner surface of ST as a lubricant Specified lubricant TIRE LUBE 1 3 _ 4M0100B 1 Bushing 2 Bushing B 3 Bushing C 4 Front 5 Outside of body 54 0366 1 Press 2 Bushing 3 Lateral link S4M0365A 1 Press 2 Lateral link RS 17 LATERAL LINK REAR SUSPENSION 2 Press the ST plunger until bushing flange pro 3 Turn the lateral link upside down Press the ST trudes beyond lateral link plunger in the direction opposite that outlined
360. sembling be careful to prevent any metal chip dust or dirt from entering the wheel cylinder S4M0455A 1 Cup 2 Piston 3 Apply rubber grease to the boot inside as shown in figure CAUTION Never use brake grease Grease NIGLUBE RX 2 Part No 003606000 54 0456 INSPECTION 1 Inspect the wheel cylinder for leakage 2 If the deformation or wear of back plate shoe etc are notable replace them BR 35 MASTER CYLINDER BRAKE 11 Master Cylinder 3 Pry up the pawl and remove the piston retainer NOTE A REMOVAL 1 Thoroughly drain the brake fluid from reservoir tank 2 Disconnect the fluid level indicator harness con nector 3 Remove the brake pipes from master cylinder 4 Remove the master cylinder mounting nuts and take out master cylinder from brake booster CAUTION Be extremely careful not to spill the brake fluid Brake fluid spilt on the vehicle body will harm the painted surface wipe it off quickly if spilt B INSTALLATION 1 To install the master cylinder to the body re verse the sequence of removal procedure Tightening torque Master cylinder mounting nut 14 1 4 kgf m 10 1 ft lb Piping flare nut 15 1 5 kgf m 10 8 ft lb CAUTION Be sure to use recommended brake fluid 2 Bleed air from the brake system lt Ref to BR 46 PROCEDURE Air Bleeding gt C DISASSEMBLY 1 PRECAUTIONS FOR
361. sen the adjusting screw 2 Rotate the input shaft so that the rack is in the straight ahead direction 3 Apply grease to the sleeve Vi TaN ote B4M1130B 1 Adjusting screw 2 Lock nut 3 Spring 4 Sleeve cee 4 Tighten the adjusting screw by two threads G4M0121 5 Apply liquid packing to at least 1 3 of entire perimeter of adjusting screw thread Liquid packing THREE BOND 1141 S4M0385A 1 Apply liquid packing to at least 1 3 of entire perimeter 6 Tighten the adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft lb and back off 25 7 Install the lock nut While holding adjusting screw with a wrench tighten the lock nut using ST ST 926230000 SPANNER Tightening torque Lock nut 39 N m 4 0 kgf m 29 ft lb NOTE e Hold the adjusting screw with a wrench to vent it from turning while tightening lock nut e Make adjustment so that the steering wheel can be rotated fully from lock to lock without binding 24 Check for service limit as per article of Service limit Ref to PS 42 INSPECTION Steering Gearbox Make replacement and adjustment if necessary 25 Install the boot to the housing NOTE e Before installing boot be sure to apply grease to the groove of tie rod Install fitting portions of boots to the following portions in both sides of assembled steering gear box The groove on gearbox The groove on the rod e Make sure that the
362. sible causes Take the follow ing step first Remove the pipe assembly B from the valve housing and close the circuit with ST ST 926420000 PLUG Turn the steering wheel from lock to lock 30 to 40 times with the engine running then make comparison of the leaked portion between im mediately after and several hours after this op eration CAUTION If leakage from f is noted again The oil seal of pinion and valve assembly is damaged Replace pinion and valve assembly with a new one Or replace the oil seal and the parts that are damaged during disassembly with new ones If oil stops leaking from f The oil seal of rack housing is damaged Re place the oil seal and the parts that are dam aged during disassembly with new ones F ADJUSTMENT 1 Adjust the front toe Standard of front toe IN 3 OUT 1 mm IN 0 12 OUT 0 039 in S4M0386A 1 Lock nut 2 Adjust the steering angle of wheels Standard of steering angle TURBO Sedan OUTBACK Inner wheel 3 36255 1 52 31 35 1 52 4 05 1 5 Outer wheel 29 35 1 5 3 If the steering wheel spokes are not horizontal when wheels are set in the straight ahead position and error is more than 5 on the periphery of steer ing wheel correctly re install the steering wheel 0 0 67 in 54 0188 4 If the steering wheel spokes are not horizontal with vehicle set in the straight ahead position after thi
363. splay Refers to vehicle acceleration detected by the analog G sensor It appears on the select monitor display in volts ii EE mon Motor relay operation monitor signal Stop light switch Stop light switch signal ABS signal to ABS operation signal from ABS contro TCM module to TCM ABS operation signal from ABS control ABS AT control module to TCM operation ABS operation signal signal G sensor output voltage ABS 94 ABS DIAGNOSTICS DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR efe ee sie Wian Al ez e A eee mee eee ne ei mi han we UG E de Ree ce io Motte ae ep VR os Sia e e Ea LA NR da toa umi Se t ER evi ir tta ss Leu Wis da t mt ge ES uta a SA Ric ABS 95 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS 13 Diagnostics Chart with Subaru Select Monitor A COMMUNICATION FOR INITIALIZING IMPOSSIBLE DIAGNOSIS e Faulty harness connector TROUBLE SYMPTOM ABS warning light remains on WIRING DIAGRAM BATTERY SBF 1 ONO IQs GENERATOR Y LL r 9
364. step 12 Replace the G Measure the voltage between G sensor con 0 9 V when G sensor is sensor Ref to nector terminals inclined backwards to 902 ABS 23 G Sen Connector amp terminal Sor 292 No 2 No 3 CHECK ABSCM amp H U Is the same diagnostic trouble the Go to step 13 1 Turn the ignition switch to OFF code as the current diagno ABSCM amp H U 2 Connect all connectors sis still being output Ref to ABS 7 3 Erase the memory ABS Control Mod 4 Perform the inspection mode ule and Hydraulic 5 Read out the diagnostic trouble code Control Unit ABSCM amp H U CHECK ANY OTHER DIAGNOSTIC TROU other diagnostic trouble Proceed with the A temporary poor BLE CODES APPEARANCE codes being output diagnosis corre contact sponding to the diagnostic trouble code e c NI wj Inner antem eT cma eR mum SN f f naam n Fn ABS 182 GENERAL DIAGNOSTICS TABLE ABS DIAGNOSTICS pO 14 General Diagnostics Table A INSPECTION Probable faulty units parts ABSCM amp H U solenoid valve ABS sensor e Brake caliper amp piston pads e Wheel alignment e Tire specifications tire wear and air pressures e Incorrect wiring or piping connections e Road surface uneven camber ABSCM amp
365. t Rear differential member rear RS 5 HEAR SUSPENSION Tightening torque N m kgf m ft Ib T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 T11 20 2 0 14 5 25 2 5 18 1 45 4 6 33 2 55 5 6 41 70 7 1 52 90 9 2 66 100 10 2 74 115 11 7 85 130 13 3 96 135 13 8 100 220 22 4 162 GENERAL DESCRIPTION REAR SUSPENSION C CAUTION e Wear working clothing including a cap protec tive goggles and protective shoes during opera tion e Remove contamination including dirt and corro sion before removal installation or disassembly Keep the disassembled parts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement e Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or safety stands at the specified points Apply grease onto sliding or revolution surfaces before installation _ Before installing O rings or snap rings apply suf ficient amount of grease to avoid damage and de formation Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice Before dis
366. tance less than 0 5 Repair open circuit in harness between battery and Relay holder connecior Is the voltage more than 10 V 8264 No 1 Chassis ground ABS relay CHECK GROUND CIRCUIT OF ABS RELAY Repair open circuit 1 Turn the ignition switch to OFF between ABS 2 Measure the resistance between ABS relay relay and chassis connector and chassis ground ground Connector amp terminal B264 No 3 Chassis ground CHECK ABS RELAY 1 Connect the battery to ABS relay terminal No 1 and 3 2 Measure the resistance between ABS relay terminals CHECK INPUT VOLTAGE OF ABSCM amp H U 1 Run the engine at idle 2 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 1 Chassis ground Is the resistance less than 5 2 Replace the ABS relay Is the resistance less than 10 2 Repair harness connector between battery ignition switch and ABSCM amp H U Is the voltage between 10 and 15 V ABS 83 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Check Yes Repair the ABSCM amp H U ground harness 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 23 Chassis ground CHECK MOTOR OPERATION
367. tem wiring harness when Servicing the ABS sensor ABS contro module and hydraulic control unit B INSPECTION Before performing diagnostics check the following items which might affect ABS problems 1 BATTERY Measure the battery voltage and specific gravity of electrolyte Standard voltage 12 V or more Specific gravity Above 1 260 2 BRAKE FLUID 1 Check the brake fluid level 2 Check for brake fluid leakage 3 HYDRAULIC UNIT Check the hydraulic unit e With brake tester lt Ref to ABS 9 CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH BRAKE TESTER INSPECTION ABS Control Module and Hydraulic Control Unit ABSCM amp H U e Without brake tester Ref to ABS 8 CHECK ING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE INSPECTION ABS Contro Module and Hydraulic Control Unit AB SCM amp H U 4 BRAKE DRAG Check for brake drag 5 BRAKE PAD AND ROTOR Check the brake pad and rotor e Front Ref to BR 17 INSPECTION Front Brake Pad and Ref to BR 18 INSPECTION Front Disc Rotor e Rear Ref to BR 24 INSPECTION Rear Brake Pad and Ref to BR 26 INSPECTION Rear Disc Rotor or Ref to BR 31 INSPEC TION Rear Drum Brake Shoe and Ref to BR 32 INSPECTION Rear Drum Brake Drum 6 TIRE Check the tire specifications tire wear and air pres sure Ref to WT 2 SPECIFICATIONS General Description ABS 9 GENERAL DESCRIPTION ABS DIAGNOSTICS
368. tep 3 CHECK SOURCES OF SIGNAL NOISE Go to step 4 Properly install the car telephone or the wireless trans mitter Go to step 5 CHECK SOURCES OF SIGNAL NOISE Install the noise sources apart from the sensor har ness Replace the ABSCM amp H U Hef to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U Proceed with the diagnosis corre sponding to the diagnostic trouble code Are noise sources such as an antenna installed near the sensor harness CHECK ABSCM amp H U 1 Connect all connectors 2 Erase the memory 3 Perform the inspection mode 4 Read out the diagnostic trouble code Is the same diagnostic trouble code as in the current diagno sis stil being output Go to step 6 CHECK ANY OTHER DIAGNOSTIC TROU BLE CODES APPEARANCE Are other diagnostic trouble codes being output A temporary poor contact ABS 67 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS ABS 68 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS V DTC 42 SOURCE VOLTAGE IS ABNORMAL DIAGNOSIS Power source voltage of the ABSCM amp H U is low or high TROUBLE SYMPTOM e ABS does not operate ABS 69 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY GENERATOR IGNITION SWITCH RELAY oa
369. th 147 5 296 5 688 rake pressure with engine 15k f 33 Ib 54 k m 768 psi 58 k cm 25 psi running and vacuum at 66 7 kPa o E g cm 2 TU a g 825 psi 500 mmHg 19 69 inHg 30 kgf 66 Ib 93 kg cm 1 323 psi Brake edal Free la 1 3mm 0 04 as 0 12 in did Depress brake pad with a force of less than 10 1 kgf 2 Ib BR 3 GENERAL DESCRIPTION BRAKE B COMPONENT 1 FRONT DISK BRAKE NON TURBO MODEL 17 10 ga To 12 7 14 13 12 11 BRO097 1 Caliper body 9 Support 17 Lock pin sleeve 2 Air bleeder screw 10 Pad clip 3 Guide pin Green 11 Outer shim 4 boot 12 Inner shim Tightening torque N m kgf m ft Ib b Piston seal 13 Pad Outside T1 8 0 8 5 8 6 Piston 14 Pad Inside 12 18 1 8 13 0 7 Piston boot 15 Disc rotor T3 26 5 2 70 19 5 8 Lock pin Yellow 16 Disc cover T4 80 8 2 59 BR 4 GENERAL DESCRIPTION BRAKE e TURBO MODEL 4 4 7 10 11 14 13 12 2 BRO0098 1 Caliper body Air bleeder screw Guide pin Green Pin boot Piston seal Piston Piston boot Boot ring 9 10 11 12 13 14 15 16 Lock pin Support Pad clip Yellow Outer shim Inner shim Pad Outside Pad Inside Disc rotor BR 5 17 Disc cover 18 Bush Tightening torque N m kgf m ft lb T1 8 0 8 5
370. th new ones 2 Thoroughly wash the parts and allow to dry They must be kept free from cleaning oil and dust 3 Reassembly procedure must be performed in clean place Ensure that the parts are kept away from the waste threads or other dust parti cles 4 Cleaning oil tends to stay inside the front casing Remove it completely by blowing com pressed air b Ensure that the parts are free from rust Use specified hydraulic oil for rust prevention after cleaning and drying 6 Reverse the sequence of disassembly pro cedures 2 Apply the grease to the oil seal and inner surface of front casing at bearing location CAUTION Make sure that the front body internal surfaces are free from damage 3 Attach ST to the front body Using a press install the oil seal ST 34199AE030 B4M1667A 4 Press fit the shaft assembly into the front body 5 Apply the specified hydraulic to the O rings and fit them into the front casing PS 61 OIL PUMP POWER ASSISTED SYSTEM POWER STEERING 6 Install the side plate to the front casing 10 Install the cam ring to the front casing securing CAUTION with knock pins Use care not to let side plate gall CAUTION Do not use hammer to fit knock pins in position 11 Mount the O ring on the front casing 1 Front casing 2 O ring 3 Side plate 1 Rotor 7 Install the cam ring to the front casing with align E 2 Reiko ment mark facing forward 4 Cam ring b
371. th Diag diagnosis Diagnostics Chart nostic Connector lt Ref to ABS 29 Diagnos with Diagnostic tics Chart with Diagnosis Connector Connector Ref NOTE to ABS 29 Diag For diagnostic trouble code DTC list refer to nostics Chart with List of Diagnostics Trouble Code DTC Ref Diagnosis Con to ABS 24 WITHOUT SUBARU SELECT nector gt MONITOR LIST List of Diagnostics Trouble Code DTC gt 2 Repair the troubie cause 3 Perform the clear memory mode lt Ref to ABS 22 WITHOUT SUBARU SELECT MONI TOR OPERATION Clear Memory Mode gt 4 Perform the inspection mode lt Ref to ABS 21 Inspection Mode gt 5 Calling up the diagnostic trouble code DTC lt Ref to ABS 20 Read Diagnostic Trouble Code DTC gt ABS 3 BASIC DIAGNOSTIC PROCEDURE ABS DIAGNOSTICS 2 WITH SUBARU SELECT MONITOR CAUTION Remove foreign matter dust water etc from the ABSCM amp H U connector during removal and instal lation NOTE To check harness for broken wires or short circuits shake it while holding it or the connector Check the list for interview lt Ref to ABS 26 WITH SUBARU SELECT MONITOR LIST List of Diagnos tics Trouble Code DTC gt CHECK PRE INSPECTION Is unit that might influence the 1 Ask the customer when and how the trouble ABS problem normal occurred using interview checklist Ref to ABS 6 Check List for Interview 2 Before pe
372. the groove on ends of cylinder and piston boot onto cylinder Grease NIGLUBE RX 2 Part No 003606000 5 Insert the piston into cylinder CAUTION Do not force the piston into cylinder 1 Piston 2 Piston boot 6 Position the boot in grooves on cylinder and pis ton 1 Piston 2 Piston boot 3 Caliper body 4 Piston seal 7 Apply a coat of specified grease to the lock pin and guide pin outer surface cylinder inner surface and boot grooves Grease NIGLUBE RX 2 Part No 003606000 BR 21 FRONT DISC BRAKE ASSEMBLY BRAKE 8 Install the lock and guide pin boot on support 1 Pin boot 2 Lock pin or guide pin 3 Apply grease 2 TURBO MODEL 1 Clean the caliper body interior using brake fluid 2 Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Insert the piston into cylinder CAUTION Do not force the piston into cylinder B4M0771 5 Apply a coat of specified grease to the boot and fit in the groove on ends of cylinder and piston Grease NIGLUBE RX 2 Part No 003606000 To facilitate installation fit the boot starting with pis ton end 54 0448 1 Piston boot 2 Boot ring 3 Piston seal 4 Caliper body 6 Position the boot in grooves on cylinder and pis ton 7 Install t
373. the other Poorreturn of steering wheel to center Steering wheel surges when turning Replace adjust or instruct cus tomer PS 74 GENERAL DIAGNOSTIC TABLE POWER ASSISTED SYSTEM POWER STEERING 1 NOISE AND VIBRATION CAUTION Don t keep the relief valve operated over 5 sec onds at any time or inner parts of the oil pump may be damaged due to rapid increase of fluid temperature NOTE e Grinding noise may be heard immediately after the engine start in extremely cold condition In this case if the noise goes off during warm up there is no abnormal function in the system This is due to the fluid characteristic in extremely cold condition e Oil pump makes whine or growl noise slightly due to its mechanism Even if the noise can be heard when steering wheel is turned at stand still there is no abnormal function in the system provid ed that the noise eliminates when the vehicle is running When stopping with service brake and or parking brake applied power steering can be operated easily due to its light steering effort If doing so the disk rotates slightly and makes creaking noise The noise is generated by creaking between the disk and pads If the noise goes off when the brake is re leased there is no abnormal function in the system There may be a little vibration around the steer ing devices when turning steering wheel at stand still even though the component parts ar
374. the voltage more than 10 V Repair open circuit in harness between battery and relay holder connector Go to step 2 2 CHECK RELAY HOLDER is the fuse blown out Replace the fuse Go to step 3 3 CHECK INPUT VOLTAGE OF ABS RELAY 1 Install the fuse 2 Remove the ABS relay 3 Turn the ignition switch to ON 4 Measure the voltage between ABS relay connector and chassis ground Connector amp terminal B264 No 2 Chassis ground CHECK INPUT VOLTAGE OF ABS RELAY Measure the voltage between ABS relay con nector and chassis ground Connector amp terminal B264 1 Chassis ground 1 Turn the ignition switch to OFF 2 Measure the resistance between ABS relay connector and chassis ground Connector amp terminal B264 No 3 Chassis ground CHECK ABS RELAY 1 Connect the battery to ABS relay terminal No 1 and 3 2 Measure the resistance between ABS relay terminals CHECK INPUT VOLTAGE OF ABSCM amp H U 1 furn the ignition switch to OFF 2 Disconnect the connector from ABSCM amp H U 3 Run the engine at idle 4 Measure the voltage between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 1 Chassis ground 1 Turn the ignition switch to OFF 2 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 23 Chassis ground 10
375. tion or damage of helper in strut assembly and or shock Replace absorber 9 leakage of damper strut and or shock absorber 3 NOISE Possible causes Countermeasures 1 Wear or damage of damper strut and or shock absorber component parts 2 Loosening of suspension link installing bolt Retighten to the specified torque 8 Deformation or loss of bushing 4 Unsuitability of maximum and or minimum length of damper strut and or Replace with proper parts shock absorber 6 Wear or damage of ball join 7 Deformation of stabilizer clamp FS 26 REAR SUSPENSION te General 6 RU II ER 2 a c EIU eu erp adu 3 sFREAN 4 Rear Trailing 5 Roar Stulen Lateral ei tete eri nt D svi 7 dear ChOSSIMEMDEN ub i M pesa 8 General Diagnostic Table GENERAL DESCRIPTION REAR SUSPENSION 1 General Description A SPECIFICATIONS Sedan Wagon Sedan Turbo Non turbo Turbo Non turbo Camber tolerance 1048 1 2 mm 0 039 0 079 Each toe in angle 0907730 Total toe in angle 09 15 Wheel arch height 376 mm 381 mm 376 mm 381 mm 386 mm tolerance 12 mm 30 47 in 14 80 in 15 0 in 14 80 in
376. tor gt ABS 40 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS G DTC 27 ABNORMAL ABS SENSOR OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH REAR LH DIAGNOSIS Faulty ABS sensor Broken wire input voltage too high Faulty harness connector TROUBLE SYMPTOM ABS does not operate ABS 41 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT N i 1 i 1 I 1 I t SHIELD JOINT P CONNECTOR 1 Lise B200 gar Fe MSc aEZxZ10 0c lll I ZI um um wm NR GR xe um WS UR de Am ri 5 ee nen eae ED REAR REAR ABS ABS SENSOR LH SENSOR RH 1 2 3 4 5 6 7 8 9 10 111121131415 er 16 17118 19 20 21 22 27 28 29 30 31 718 20121122123124 0084 5 42 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS Ye Ne 1 CHECK ABS SENSOR Is the resistance between 1 Go to step 2 Replace the A
377. tor B terminal Chassis ground CHECK BATTERY TERMINAL Turn the ignition switch to OFF Are the positive and negative battery terminals tightly clamped Is the voltage more than 10 V Tighten the clamp of terminal CHECK INPUT VOLTAGE OF RELAY HOLD ER 1 Turn the ignition switch to OFF 2 Remove the fuse 3 Measure the voltage between ABS relay connector and chassis ground Go to step 3 Connector amp terminal Go to step 4 B225 No 5 Chassis ground 5 CHECK INPUT VOLTAGE OF ABS RELAY 15 the voltage more than 10 V Go to step 6 Repair open circuit 1 Install the fuse in harness 2 Remove the ABS relay between battery 3 Turn the ignition switch to ON and Relay holder 4 Measure the voltage between ABS relay connector connector and chassis ground Connector amp terminal B264 No 2 Chassis ground CHECK INPUT VOLTAGE OF ABS RELAY 5 the voltage more than 10 V Repair harness Measure the voltage between ABS relay con connector nector and chassis ground between battery Go to step 8 Go to step 9 Repair open circuit in harness between battery and Relay holder connector Connector amp terminal ignition switch and 8264 No 1 Chassis ground ABS relay CHECK GROUND CIRCUIT OF ABS RELAY Repair open circuit 1 Turn the ignition switch to OFF between ABS 2 Measure the resistance between ABS relay
378. ts from the bracket 1 Snap pin and clevis pin 2 Four brake booster installing nuts 3 Remove the brake booster while shunning brake pipes NOTE Be careful not to drop the brake booster Brake booster should be discarded if it has been dropped Use sp cial care when handling the operating rod If excessive force is applied to operating rod suffi cient to cause a change in the angle in excess of 3 it may result in damage to the power piston cyl inder Use care when placing the brake booster on the floor Do not change the push rod length If it has been changed reset the projected length L to the stan dard length Standard L 10 4 0 41 G4M0424 CAUTION If external force is applied from above when brake booster is placed in this position the res in portion as indicated by be dam aged S4M0464A 1 Force BR 38 BRAKE BOOSTER BRAKE B INSTALLATION 1 Mount the brake booster in position 2 Connect the operating rod to brake pedal with clevis pin and snap pin 4 0117 1 Nuts 2 pin 3 Snap pin 4 Operating rod 3 Connect the vacuum hose to brake booster 4 Mount the master cylinder onto brake booster 5 Connect the brake pipes to master cylinder 6 Connect the electric connector for brake fluid level indicator 7 Adjust the operating rod of brake booster Standard L LHD model 144 6
379. two or three times and then hold it de pressed 7 Loosen the bleeder screw approximately 1 4 turn until a small amount of brake fluid drains into the container and then quickly tighten the screw 44 BRAKE FLUID BRAKE 8 Repeat steps 6 and 7 above until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube NOTE Add brake fluid as necessary while performing the air bleed operation in order to prevent the tank from running short of brake fluid 9 After completing the bleeding operation hold the brake pedal depressed and tighten the screw and install bleeder cap Tightening torque Bleeder screw 8 N m 0 8 kgf m 5 8 ft lb 10 Bleed air from each wheel cylinder using the same procedures as described in steps 6 through 7 above 11 Depress the brake pedal with a force of approx imately 294 N 30 kgf 66 Ib and hold it there for ap proximately 20 seconds At this time check the pedal to see if it shows any unusual movement Visually inspect the bleeder screws and brake pipe joints to make sure that there is no fluid leakage 12 Install the wheels and drive vehicle for a short distance between 2 to 3 km 1 to 2 miles to make sure that brakes are operating properly BR 45 AIR BLEEDING BRAKE 15 Air Bleeding 4 Close the outlet plug with your finger and re lease the brake pedal A PROCEDURE CAUTION The FMVSS 116 fresh DOTS or 4 brake f
380. ure to tighten axle nut to specified torque Do not overtighten it as this may dam age wheel bearing 9 After tightening axle nut lock it securely s I m s 457 gt gt r ppm T 7 gt gt 5 A N cs 5 Insert the DOJ spline end into the bore of side oil seal and remove ST CAUTION Do not allow DOJ splines to damage side oil seal ST 28099PA090 SIDE SEAL PROTEC TOR DS 40 REAR DRIVE SHAFT C DISASSEMBLY 1 Straighten the bent claw of larger end of DOJ boot 2 Loosen the band by means of screwdriver or pli ers with care of not damaging boot G4M028 1 3 Remove the boot band on the small end of DOJ boot in the same manner 4 Remove the larger end of DOJ boot from DOJ outer race 5 Pry and remove the round circlip located at the neck of DOJ outer race with a screwdriver 6 Take out the DOJ outer race from shaft assem bly DRIVE SHAFT SYSTEM 7 Wipe off the grease and take out balls CAUTION The grease is a special grease grease for con stant velocity joint Do not confuse with other greases NOTE Disassemble exercising care not to lose balls 6 pcs B4M0227E A Outer race B Grease 8 To remove the cage from the inner race turn the cage by a half pitch to the track groove of the inner race and shift the cage 9 Remove snap ring which fixes inner race to shaft by using pliers 10 Take out the DOJ inner race 11
381. uring strut mount to body REAR SUSPENSION B INSTALLATION 1 Tighten the self locking nut used to secure strut mount to car body CAUTION Discard the loosened self locking nut and re place with a new one Tightening torque 20 N m 2 0 kgf m 14 5 ft lb 2 Tighten the bolts which secure rear strut to hous ing Tightening torque 220 22 4 kgf m 162 ft lb CAUTION Discard the loosened self locking nut and re place with a new one 3 Install the brake hose to lower side of strut then insert brake hose clip CAUTION e Check that the hose clip is positioned proper ly Check the brake hose for twisting or exces sive tension Model equipped with ABS Do not subject the ABS sensor harness to exc es sive tension 4 Lower the vehicle and tighten wheel nut Tightening torque 90 9 2 kgf m 66 ft lb 5 Sedan model Install the rear seat backrest and rear seat cushion Wagon model Install the strut cap to rear quarter trim NOTE Check wheel alignment and adjust if necessary C DISASSEMBLY For disassembly of rear strut refer to procedures outlined under front strut as a guide lt Ref to FS 21 DISASSEMBLY Front Strut gt D ASSEMBLY Refer to Front Strut as a guide for assembly proce dures lt Ref to FS 22 ASSEMBLY Front Strut gt E INSPECTION Refer to Front Strut as a guide for inspection proce dures lt Ref to FS 23 INSPECTION Front Strut gt F DIS
382. urrent diagno sis still being output Are other diagnostic trouble codes being output ABS 149 Yes Go to step 2 Repair the con nector Replace the ABSCM amp H U Ref to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Proceed with the diagnosis corre sponding to the diagnostic trouble code Replace the ABSCM amp H U Ret to ABS 7 ABS Control Mod ule and Hydraulic Control Unit ABSCM amp H U gt Go to step 3 Go to step 4 A temporary poor contact DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS ABS 150 en rey m rrr rr c DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS AA DTC 52 OPEN CIRCUIT IN MOTOR RELAY CIRCUIT DIAGNOSIS Faulty motor Faulty motor relay Faulty harness connector TROUBLE SYMPTOM ABS does not operate ABS 151 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY SBF 1 1 22 SBF 4 OAD SBF HOLDER Ga LJ IGNITION SWITCH RELAY HOLDER B20 90 60 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT SOLENOID VALVE FL INLET FR OUTLET L BL INLET J HL OUTLET HR INLET RR OUTLE PUMP MOTOR a TST s EEA EEE lel be 091191818118 un 9 20 p ee zs 25 0088
383. usting the position of stop light switch CAUTION Be careful not to rotate the stop light switch BR 55 STOP LIGHT SWITCH BRAKE D ADJUSTMENT Loosen the lock nut and adjust the stop light switch position until the clearance between threaded end of the stop light switch and the stopper becomes 0 3 mm 0 012 in Then tighten the lock nut 4 0617 56 GENERAL DIAGNOSTICS BRAKE 20 General Diagnostics A INSPECTION Bo oe ee ee te Trouble and possible cause Corrective action 1 Insufficient braking 1 Fluid leakage from the hydraulic mechanism Repair or replace cup piston seal piston boot master cylinder piston kit pipe or hose 2 Entry of air into the hydraulic mechanism Bleed the air 3 Excessively wide shoe clearance Adjust the clearance 4 Wear deteriorated surface material adhering Replace grind or clean water or fluid on the lining 5 Improper operation of master cylinder disc cal iper brake booster or check valve 1 Fluid on the lining drum or rotor Eliminate cause of fluid leakage clean or replace 2 Drum or rotor eccentricity Correct or replace the drum or rotor 3 Worn brake drum or damage to the drum Correct by grinding or replace caused by sand 4 Improper lining contact deteriorated surface Correct by grinding or replace material improper inferior material or wear 5 Deformed back plate Correct or replace 6 Improper tire inflation
384. ut Crown gear runout Less than 0 05 mm 0 0020 in If the crown gear runout exceeds 0 05 mm 0 0020 in replace the crown gear 4 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION Inspect the tooth contact between crown gear and driven pinion Ref to DI 24 ASSEMBLY Rear Differential gt 5 TOTAL PRELOAD Using a gauge check the turning resistance in crease Total preload 2 9 10 8 N m 0 3 1 1 kgf 0 7 2 4 Ib If the increase of the resistance is not within the specification adjust the side bearing retainer shims F ADJUSTMENT 1 SIDE GEAR BACKLASH Adjust the side gear backlash Ref to DI 24 ASSEMBLY Rear Differential gt 2 CROWN GEAR BACKLASH Adjust the crown gear backlash Ref to 01 24 ASSEMBLY Rear Differential 3 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION Adjust the tooth contact between crown gear and drive pinion gear Ref to DI 24 ASSEMBLY Rear Differential 4 TOTAL PRELOAD Adjust the side bearing shim Ref to DI 24 ASSEMBLY Rear Differential DI 34 REAR DIFFERENTIAL FRONT OIL SEAL DIFFERENTIALS 5 Rear Differential Front Oil Seal A INSPECTION Make sure that there is no oil leakage from front oil seal If there is any oil leakage replace the oil seal B REPLACEMENT 1 Set the vehicle on the lift 2 Disconnect the ground terminal from battery 3 Move the select lever or gear shift lever to N 4 Relea
385. ve but one bolt B3M1587C A Matching mark 10 Remove the two bolts which hold center bear ing to the vehicle body DS 14 PROPELLER SHAFT 11 Remove the propeller shaft from the transmis sion CAUTION not to damage oil seals and frictional surface of sleeve yoke Cover the center exhaust pipe with a cloth to keep off any ATF or oil spilled from transmis sion when removing propeller shaft NOTE Be sure to use an empty oil can to catch oil flow ing out when removing propeller shaft Be sure to plug the opening in transmission after removal of propeller shaft cH OW 12 Install the extension cap to transmission NOTE If extension cap is not available place vinyl bag over opening and fasten with string to prevent gear oil or ATF from leaking G3M0025 A Extension cap DRIVE SHAFT SYSTEM B INSTALLATION 1 Insert the sleeve yoke into the transmission and attach center bearing to body Tightening torque 52 5 3 kgf m 38 3 ft lb 2 Align the matching marks and connect the flange yoke and rear differential Tightening torque 31 3 2 kgf m 23 1 ft lb B3M1587C A Matching mark 3 Install the differential mount front cover Tightening torque 88 N m 9 0 kgf m 65 ft lb 4 Install the rear differential protector If equipped 5 Install the rear exhaust pipe and muffler DS 15 PROPELLER SHAFT
386. ver T5 181 4 18 50 133 8 10 Front oil seal 21 Air breather cap 11 Companion flange 22 Stud bolt DI 5 DIFFERENTIALS 3 REAR DIFFERENTIAL MOUNTING SYSTEM 1 2 3 4 5 6 Differential front member Plate Crossmember Differential rear member Differential mount lower bracket TURBO model Differential mount lower bracket Non turbo model GENERAL DESCRIPTION 7 8 9 10 Stopper Dynamic damper Differential mount bracket Differential mount front cover DI 6 3 DRO0002 Tightening torque N m kgf m ft Ib T1 T2 19 14 T5 T6 20 2 0 14 5 33 3 4 24 3 65 6 6 47 9 70 7 1 51 6 90 9 2 66 4 100 10 2 73 8 GENERAL DESCRIPTION DIFFERENTIALS CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during opera tion e Remove contamination including dirt and corro sion before removal installation or disassembly e Keep the disassembled parts in order and pro tect them from dust or dirt e Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement e Be careful not to burn your hands because each part on the vehicle is hot after running Use SUBARU genuine gear oil grease etc or the equivalent Do not mix gear oil grease etc with that of another grade or from other manufacturers e Be sure to
387. w until it no longer tightens 10 Using a wrench 32 mm 1 26 in width across flats or adjustable wrench remove the tie rod CAUTION Check joint for free play and tie rod for bends Replace if necessary Check dust seals used with tie rod end ball joint for damage or deterioration Replace if necessary 11 Loosen the adjusting screw and remove the spring and sleeve CAUTION Replace spring and or sleeve if damaged 12 Remove the two bolts securing valve assembly PS 29 STEERING GEARBOX POWER ASSISTED SYSTEM POWER STEERING 13 Carefully draw out the input shaft and remove 16 Remove the rack bushing and rack stopper the valve assembly from the rack assembly CAUTION Do not reuse removed rack bushing and circlip 17 Remove the oil seal from rack 18 Insert ST from the pinion housing side and re move the oil seal using a press ST 34099FA110 INSTALLER 14 Using a sharp pointed pliers rotate the rack stopper in the direction of the arrow until the end of the circlip comes out of the stopper Rotate the cir clip in the opposite direction and pull it out 54 0158 1 Rack stopper 54 0163 15 Pull the rack assembly from the cylinder side and draw out the rack bushing and rack stopper to 1 Press gether with the rack assembly 2 seal Be careful not to contact rack to inner wall of Biseard tihiememovad hebi ssai cylinder when drawing out Any scrat
388. ween TCM and ABSCM amp H U Is an ABSCM amp H U for model installed on a MT model CHECK SPECIFICATIONS OF THE AB SCM amp H U Check specifications of the mark to the ABSCM amp H U CC AT CD MT CHECK GROUND SHORT OF HARNESS 1 Turn the ignition switch to OFF 2 Disconnect two connectors from TCM 3 Disconnect the connector ABSCM amp 4 Measure the resistance between ABSCM amp H U connector and chassis ground Connector amp terminal F49 No 3 Chassis ground CHECK TCM 1 Connect all connectors to TCM 2 Turn the ignition switch to ON 3 Measure the voltage between TCM connec jor terminal and chassis ground Connector amp terminal Is the resistance more than 1 MQ Is the voltage between 10 and 15 V NON TURBO MODEL B54 19 Chassis ground TURBO MODEL B55 No 21 Chassis ground 5 CHECK OPEN CIRCUIT OF HARNESS Is the voltage more than 10 V Repair harness Measure the voltage between ABSCM amp H U connector connector and chassis ground between TCM and Connector amp terminal ABSCM amp H U 49 3 Chassis ground F49 No 31 Chassis ground CHECK POOR CONTACT IN CONNECTORS Repair the con nector Is there poor contact in con nectors between TCM and ABSCM amp H U Is the same diagnostic trouble c
389. work accidental damage as well as inevita ble damage to some related parts must be taken into account and spare parts for them must also be prepared However it is essential to pinpoint the cause of trouble and limit the number of replace ment parts as much as possible 1 RACK HOUSING ASSEMBLY 1 Disconnect the four pipes from the gearbox NOTE Remove the pipes E and F as a single unit being fixed at the clamp plate 2 Secure the gearbox removed from the vehicle in vice using ST ST 926200000 CAUTION Secure the gearbox in a vice using the ST as shown Do not attempt to secure it without this ST STAND SES mug li 15 S S4M0143A 3 Remove the tie rod end plate ST0084 4 Remove the tie rod end and lock nut from the gearbox 5 Remove the small clip from the boot using pliers and move the boot to the tie rod end side 54 0144 1 5 28 STEERING 6 Using standard screwdriver remove the band from the boot S4M0145C 1 Band 7 Extend the rack approximately 40 mm 1 57 in out Unlock the lock wire at lock washer on each side of tie rod end using a standard screwdriver CAUTION Be careful not to scratch rack surface as oil leaks may result 40 mm 1 57 in S4M0146C 1 Lock washer 8 Using ST loosen the lock nut ST 926230000 SPANNER S4M0147C POWER ASSISTED SYSTEM POWER STEERING 9 Tighten the adjusting scre
390. y A REMOVAL 1 Loosen the wheel nuts jack up the vehicle sup port it with rigid racks and remove the wheel 2 Release the parking brake 3 Remove the brake drum from brake assembly lt Ref to BR 32 REMOVAL Rear Drum Brake Drum gt 4 Remove the brake shoe lt Ref to BR 30 RE MOVAL Rear Drum Brake Shoe gt 5 Unscrew the brake hose flare nut and disconnect the brake hose 6 Remove the hub lt Ref to DS 23 REMOVAL Rear Axle gt 7 Disconnect the ABS sensor from back plate only vehicle equipped ABS 8 Remove the brake assembly 9 Remove the bolts installing the wheel cylinder on back plate and remove it B INSTALLATION 1 Clean the back plate and wheel cylinder 2 Install the wheel cylinder on back plate and tighten bolts Tightening torque 10 1 0 kgf m 7 2 ft lb 3 Apply grease to the portions indicated by arrows in Figure Brake grease Dow Corning Molykote No 7439 Part No 725191460 4 Install the brale assembly on hopusing and tighten bolts to install the back plate Tightening torque 53 5 4 kgf m 39 1 ft lb 5 Install the hub lt Ref to DS 26 INSTALLATION Rear Axle gt BR 33 REAR DRUM BRAKE ASSEMBLY BRAKE 6 Connect the brake hose and tighten the brake hose flange nut Tightening torque 15 1 5 kgf m 10 8 ft lb 7 Connect the ABS sensor to back plate only ve hicle equipped with ABS Tightening
391. ydraulic Control Unit ABSCM amp H U gt ABS 36 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS C DIAGNOSTIC TROUBLE CODE DTC DOES NOT APPEAR DIAGNOSIS e Diagnosis circuit is open TROUBLE SYMPTOM The ABS warning light turns on or off normally but the start code cannot be read out in the diagnostic mode ABS 37 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ABS DIAGNOSTICS WIRING DIAGRAM BATTERY SBF 3 SBF 1 D iC cd e IGNITION SWITCH al S RELAY HOLDER 13 108 E acd TURBO ENGINE MODEL 5 NON TURBO ENGINE MODEL h COMBINATION bos DIAGNOSIS INDICATOR LIGHT he TERMINAL TEGUISE srme 465 g 1112 91 14115 16 19 24 25 26 29 34135138 56 419 11132113 18 28 38 7118 RELAY HOLDER 0083 5 38 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR CHECK DIAGNOSIS TERMINAL 1 Turn the ignition switch to OFF 2 Measure the resistance between diagnosis terminals B81 and chassis ground Terminals Diagnosis terminal A Chassis ground Diagnosis terminal B Chassis ground CHECK DIAGNOSIS LINE 1 Turn the ignition switch to OFF 2 Connect the diagnosis terminal B81 to diagnosis connector B82 No 6 3 Disconnect the connector from ABSCM amp H U 4 Measure the resistance between ABSCM amp H U

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